Chevrolet - Cavalier - Workshop Manual - 1997 - 1997

Factory Workshop Manual Make Chevrolet Model Cavalier Engine and year L4-144 2.4L DOHC VIN T SFI (1997) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions Alarm Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 8 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 14 Alarm Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 16 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 17 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 18 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 19 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 21 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 22 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 23 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 24 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 25 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 26 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 27 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 28 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 29 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 30 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 31 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 32 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 33 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 34 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 35 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 36 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 37 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 38 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 39 Alarm Module: Electrical Diagrams Refer to Antitheft and Alarm Systems level diagrams. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 40 Alarm Module: Service and Repair Vehicle Theft Deterrent - Controller Learning Diagram Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 41 Vehicle Theft Deterrent - Component Changing Diagram The PASSLOCK System is designed to prevent theft even if various theft deterrent parts are changed. Parts that can no longer be changed without the possibility of going into a tamper mode are: ^ PASSLOCK Lock Cylinder ^ Instrument Panel Cluster (IPC) ^ Powertrain Control Module (PCM) If any of these parts are replaced, the vehicle may start and stall for 10 (ten) minutes (LONG TAMPER MODE). If this occurs, the system MUST go through a LONG TAMPER MODE cycle. During this time, the THEFT TELLTALE will be flashing for the full ten minutes. The IPC and PCM require the full ten minutes to complete a learn cycle. The Ignition Key MUST remain in the "RUN" position until the telltale stops flashing or the cycle will have to be repeated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Emergency Contact Module: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 46 Emergency Contact Module: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 47 Emergency Contact Module: Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Module Mounting And Wiring REMOVE OR DISCONNECT 1. Negative battery cable. 2. Open rear compartment. 3. Left inner trim panel. 4. One electrical connector. 5. Remove push pins. 6. Module. INSTALL OR CONNECT 1. Module to rear compartment brace. 2. Push pins to brace. 3. Electrical connector. 4. Rear compartment trim. 5. Close rear compartment. 6. Negative battery cable. 7. Program to match transmitter(s). Refer to "Remote Keyless Entry Module Programming". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 59 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 60 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 61 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 67 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 68 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 69 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations LH Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations > Page 74 Door Lock Relay And Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Module Mounting And Wiring REMOVE OR DISCONNECT 1. Negative battery cable. 2. Open rear compartment. 3. Left inner trim panel. 4. One electrical connector. 5. Remove push pins. 6. Module. INSTALL OR CONNECT 1. Module to rear compartment brace. 2. Push pins to brace. 3. Electrical connector. 4. Rear compartment trim. 5. Close rear compartment. 6. Negative battery cable. 7. Program to match transmitter(s). Refer to "Remote Keyless Entry Module Programming". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 81 Door Lock Relay And Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair SUNROOF MODULE Remove or Disconnect 1. Sunroof in the fully closed position. 2. Sunroof opening trim lace. 3. Sunroof control switch. 4. Headlining trim finish panel. 5. Drain hose connections from the sunroof housing. 6. Sunroof module bolts. 7. Sunroof module. Install or Connect 1. Sunroof module. 2. Sunroof module bolts. Tighten ^ Bolt to 11 Nm (97 lb. in.) 3. Drain hose connections from the sunroof housing. 4. Headlining trim finish panel. 5. Sunroof control switch. 6. Sunroof opening trim lace. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations > Page 89 Electronic Brake Control Relay: Description and Operation The Electronic Brake Control Relay is a normally-open contact type, and has special contact material to handle the high currents required for ABS VI operation. The relay allows the battery voltage and current to be supplied to the EBCM, which supplies power to the motors and solenoids. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations > Page 90 Electronic Brake Control Relay: Service and Repair REMOVE OR DISCONNECT 1. Nut attaching Electronic Brake Control Relay. 2. Electronic Brake Control Relay. INSTALL OR CONNECT 1. Electronic Brake Control Relay. 2. Nut attaching Electronic Brake Control Relay. Tighten nut to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 99 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 100 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 106 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 107 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBCM EBCM Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBCM > Page 110 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 Electronic Brake Control Module: Diagrams C1 Electronic Brake Control Module (EBCM): C1 Electronic Brake Control Module (EBCM)l: C1 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 113 Electronic Brake Control Module: Diagrams C2 Electronic Brake Control Module (EBCM)l: C2 Electronic Brake Control Module (EBCM)l: C2 (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 114 Electronic Brake Control Module (EBCM)l: C2 (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 115 Electronic Brake Control Module: Description and Operation CONTROLS, INPUTS AND OUTPUTS The controlling element of ABS VI is a microprocessor based Electronic Brake Control Module (EBCM). Inputs to the system include four wheel speed sensors, the brake switch, the brake fluid level switch, ignition switch, and unswitched battery voltage. Outputs include three bi-directional motor controls, two solenoid controls and the Electronic Brake Control Relay. A serial data line is used for service diagnostic tools (Scan Tool), assembly plant testing and control of indicator lamps in the IPC. OPERATION The EBCM monitors the speed of each wheel. If any wheel begins to approach lock-up, the EBCM controls the motors and solenoids to reduce brake pressure to the wheel approaching lock-up. Once the wheel regains traction, brake pressure is increased until the wheel again begins to approach lock-up. This cycle repeats until either the vehicle comes to a stop, the brake is released, or no wheels approach lock-up. With ETS, the EBCM monitors the wheel spin slip through the front wheel speed sensors. If either of the front wheels begins to slip, the EBCM determines the desired wheel torque needed to minimize front wheel spin. This information is sent to the Powertrain Control Module (PCM) via the serial data link. The PCM then calculates a spark retard value to achieve the requested torque and upshifts the transmission if needed. DIAGNOSTICS The EBCM monitors itself, each input and each output for proper operation. If any system malfunction is detected, the EBCM will store a DTC in nonvolatile memory (DTCs will not disappear if the battery is disconnected). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 116 Electronic Brake Control Module: Service and Repair EBCM Removal REMOVE OR DISCONNECT 1. Dash wiring harness connectors from EBCM. 2. EBCM from bracket. INSTALL OR CONNECT 1. EBCM to bracket 2. Dash wiring harness connectors to EBCM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations LH Center Of Engine Compartment Underhood fuse relay center Front View Of Engine Compartment Fuse/Relay Center Identification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 125 Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 126 Cruise Control Module: Service and Repair Cruise Control Module To Bracket Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 127 Cruise Control Module Mounting The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor to vary the throttle with each different cruise control mode. The module assembly is not serviceable. Remove or Disconnect 1. Negative battery cable. 2. Cruise control cable at engine bracket and Throttle Body Injection, (TBI) cam. 3. Cruise control cable from module assembly. 4. Electrical connector from module assembly. 5. Two 10 mm nuts from mounting studs (2.2L). Slide module from mounting bracket (2.4L). 6. Module assembly from right strut tower (2.2L). Module assembly from front of dash (2.4L). 7. Module assembly from mounting bracket (2.2L). Install or Connect 1. Module assembly to mounting bracket (2.2L). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 128 IMPORTANT Do not pre-tap screws to module without mounting bracket in between the module and the screw. The added length of the screw may damage the cruise control module. Tighten ^ Nuts to 12 N.m (106 lb. in.) 2. Module assembly to strut tower (2.2L). Module assembly to Front of Dash (2.4L). 3. Two nuts (2.2L). Tighten ^ Nuts to 25 N.m (18 lb. ft.) 4. Electrical connector to module. 5. Cruise control cable to module assembly. 6. Cruise control cable to engine bracket and TBI cam. 7. Adjust Cruise Control Cable. Refer to "Adjust Cruise Control Cable". 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 134 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 135 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 136 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 137 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 138 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 139 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 140 Audible Warning Device Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 141 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 142 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 143 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 144 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 145 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 146 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 147 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 148 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 149 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 150 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 151 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 153 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 154 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 155 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 156 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 157 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 158 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 159 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 160 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 161 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 162 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 163 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 164 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 165 Audible Warning Device Control Module: Electrical Diagrams Refer to Diagrams under Audible Warning Device. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 166 Audible Warning Device Control Module: Testing and Inspection Refer to Audible Warning Device for all Audible Warning System diagnostic information. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 167 Audible Warning Device Control Module: Service and Repair MULTI-FUNCTION ALARM ASSEMBLY Description REMOVE OR DISCONNECT 1. Negative battery cable. 2. Left sound insulator. 3. Nuts from alarm module. 4. Multi-function alarm assembly from convenience center. INSTALL OR CONNECT 1. Multi-function alarm assembly to convenience center. Tighten ^ Nuts to 6 Nm (53 lb. in.) 2. Nuts to alarm module. 3. Left sound insulator. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 172 Daytime Running Lamps Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 177 Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 178 Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 179 Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 183 Horn Relay: Service and Repair Description Remove or Disconnect 1. Convenience center. 2. Components from panel. Install or Connect 1. Install component into position and gently push forward until seated. 2. Convenience center. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Page 187 Lamp Control Module: Service and Repair Description Remove or Disconnect 1. Disable SIR system. 2. Left sound insulator. 3. Electrical connector. 4. Screws to dimmer module. Install or Connect 1. Screws to dimmer module. 2. Electrical connector. 3. Left sound insulator. 4. Enable SIR system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 192 Relay Box: Application and ID Front View Of Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 203 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 204 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 205 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 206 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 207 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 213 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 218 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 219 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 220 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 221 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 222 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Engine Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter Engine Control Module: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 231 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 232 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 233 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 234 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 235 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 236 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 237 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 676535 > Nov > 96 > PCM - New Identification Label Engine Control Module: All Technical Service Bulletins PCM - New Identification Label File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-35 Date: November, 1996 INFORMATION Subject: New PCM Identification Label Models: Late 1996 and All 1997 Passenger Cars with Powertrain Control Modules (PCM) PCM Label Effective March 7, 1996, all 1996-1/2 and 1997 model year passenger cars received a change to the identification label used on PCM's. Other than its appearance, these changes do not affect the service replacement procedure of PCM's. The illustration details the changes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls Aftermarket Accessory Usage > Page 247 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Engine Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter Engine Control Module: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 256 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 257 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 258 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 259 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 260 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 261 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 262 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 676535 > Nov > 96 > PCM - New Identification Label Engine Control Module: All Technical Service Bulletins PCM - New Identification Label File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-35 Date: November, 1996 INFORMATION Subject: New PCM Identification Label Models: Late 1996 and All 1997 Passenger Cars with Powertrain Control Modules (PCM) PCM Label Effective March 7, 1996, all 1996-1/2 and 1997 model year passenger cars received a change to the identification label used on PCM's. Other than its appearance, these changes do not affect the service replacement procedure of PCM's. The illustration details the changes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 267 Engine Control Module: Specifications PCM Retainer Bolts ............................................................................................................................. ................................................. 8-12 Nm (6-9 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 268 RH Front Corner Behind Fascia Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 271 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 272 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 273 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 274 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 275 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Engine Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 278 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 279 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 281 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 282 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 284 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 285 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 286 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 287 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 290 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 292 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 295 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 296 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 297 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 298 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 299 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Engine Control Module: Connector Views Connector View Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 303 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Specification Powertrain Control Module: C1 And C2 Pinout Description Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 2 Of 2) Connector View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 309 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 310 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 311 Specification ECM/PCM/VCM Pinout Voltage The OE manufacture does not provide an ECM/PCM/VCM connector voltage pinout chart for this vehicle, only a function description. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment Engine Control Module: Service Precautions Aftermarket (Add-on) Electrical and Vacuum Equipment Aftermarket (Add-On) Electrical and Vacuum Equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicle's electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Notice: Do not add on any Add-On vacuum operated equipment to this vehicle. Notice: Connect the Add-On electrical operated equipment to the vehicle's electrical system at the battery (power and ground). Add-On electrical equipment, even when installed to these strict guidelines, may still cause the Powertrain system to malfunction. This may also include equipment not connected to the vehicle's electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any Powertrain problem is to eliminate all Aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 314 Engine Control Module: Service Precautions Electrostatic Discharge Damage CAUTION: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Electronic components used in the control systems are often designed in order to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage; therefore, it is important to use care when handling and testing electronic components. The control module is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the control module circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the control module circuits unless instructed. Only test these circuits with a digital voltmeter J 39200, while the control module connectors remain connected to the control module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 315 Engine Control Module: Service Precautions Use of Circuit Testing Tools Do not use a test lamp in order to diagnose the Powertrain electrical systems unless specifically instructed by the diagnostic procedures. Use the Connector Test Adapter kit, J 35616 whenever diagnostic procedures call for probing any connectors. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) Engine Control Module: Description and Operation PCM Outputs (Qdsm & Odm) DESCRIPTION The Powertrain Control Module (PCM) controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface mounted Quad Driver Module (QDSM), which can independently control up to 4 outputs (PCM) terminals or Output driver Modules (ODMs) which can independently control up to 7 outputs. Not all outputs are always used. OPERATION Drivers are fault protected. If a relay or solenoid is shorted, having very low or zero resistance, or if the control side of the circuit is shorted to voltage, it would allow too much current flow into the PCM. The Driver senses this and the output is turned "OFF" or internal resistance increases to limit current flow and protect the PCM and the driver. The result is high output terminal voltage when it should be low. If the circuit from B+ to the component or if the component is open, or the control side of the circuit is shorted to ground, terminal voltage will be low. Either of these conditions is considered to be a driver fault. When and output is "ON," the terminal is grounded and its voltage will normally be low. When an output is "OFF," its terminal voltage normally will be high. QDSMs and ODMs also have a fault line to indicate the presence of a current fault to the PCM's central processor. A scan tool displays the status of the ODM fault lines as "0" = OK, "1" = Fault. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) > Page 318 Engine Control Module: Description and Operation Powertrain Control Module (PCM) PURPOSE The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control OPERATION The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics A faulty PCM will be determined in the diagnostic tables. Before replacing the PCM, a re-programming procedure should not be attempted unless instructed. If the re-programming is unsuccessful a DTC P0602 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure Engine Control Module: Service and Repair Password Learn Procedure PASSWORD LEARN PROCEDURE In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the IPC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 323 Engine Control Module: Service and Repair PCM/EEPROM Replacement/Programming Note: Clear DTCs from the PCM any time either the PCM is reprogramed or the EGR valve is replaced, or anytime the ignition switch is turned on with the EGR valve electrical connector disconnected. This is due to the auto zeroing funtion of the PCM on the EGR pintle. Notice: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM, EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. Removal Procedure Important: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to PCM (for example, battery cable, PCM Pigtail, PCM fuse, jumper cables, etc.). The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and horn. 5. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 324 6. Slide the PCM and retainer(1) from PCM bracket (2). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 7. Disconnect the PCM electrical connectors (1). 8. Remove the retainer (1) from the PCM (2). Installation Procedure Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the faulty PCM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 325 Important: Refer to the latest Techline Information on Re-Programming or Flashing procedures. 1. Slide the PCM (2) into the PCM retainer (1). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 2. Connect the PCM electrical connectors (1). 3. Slide the PCM and retainer (1) into the PCM bracket (2) slots. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 326 4. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb. ft.). 5. Connect the horn electrical connector and horn. 6. Install the horn attaching bolt. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 333 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 334 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 335 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 336 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 337 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 338 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 339 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 341 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 342 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 343 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 344 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 345 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 346 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 347 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 348 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 349 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 350 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 351 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 352 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 353 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 354 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 355 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 356 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 357 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 358 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 364 Fuel Pump Relay: Service and Repair Fuel Pump Relay Removal Procedure 1. Remove the relay center cover. 2. Remove the Fuel Pump Relay. Installation Procedure 1. Install the Fuel Pump Relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: Customer Interest PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 374 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 375 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: All Technical Service Bulletins PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 381 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 382 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 383 Ignition Control Module: Specifications Module to Cover Screws ..................................................................................................................... ........................................................ 4 Nm (35 lb. in.) Housing to Cover Screws ................................ ............................................................................................................................................ 4 Nm (35 lb. in.) Ignition Control Module Assembly to Cam Housing Bolts ........................................................................................................................ 22 Nm (16 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 386 Ignition Control Module: Connector Locations Left Rear Of Transaxle LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 387 Ignition Control Module: Diagrams Electronic Ignition Control Module: C1 And C2 Electronic Ignition Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 388 Ignition Control Module: Description and Operation The Ignition Control Module (ICM) receives the Ignition Control (IC) signals from the PCM which in turn triggers the corresponding ignition coils. Since the PCM controls spark timing and ignition control during crank and run, there is no bypass mode. The ICM is not repairable. When an ICM is replaced, transfer the remaining components to the new module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 389 Ignition Control Module: Service and Repair Ignition Control Module (ICM) Removal Procedure Tools Required J 36011 Spark Plug Removal Tool. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. Disconnect the negative battery cable. 2. Remove the accelerator and cruise control cables out of the hold down clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 390 3. Remove the fuel line retainer clip bolt. 4. Disconnect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 391 5. Remove the Ignition Coil and the Electronic Ignition Control Module (ICM) assembly to camshaft housing bolts. Notice: Spark plug boots often adhere to the spark plugs. Use tool J 36011 in order to remove by first twisting and then pulling upward on retainers. Reinstall the boots and the retainers on the ignition coil housing secondary terminals. The boots and the retainers must be in place on the ignition coil housing secondary terminals prior to the ignition coil and the electronic ignition control module assembly installation or ignition control system damage may result. 6. Remove the Ignition Coil and Electronic Ignition Control Module (ICM) assembly from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 392 7. Remove the housing to cover screws. Important: When removing the housing from the cover make sure the ground strap stays in place. 8. Disconnect the coil harness electrical connector from the Ignition Control Module. 9. Remove the housing from the cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 393 10. Remove the Ignition Control Module to cover screws. 11. Remove the Ignition Control Module from the cover. Installation Procedure Important: DO NOT wipe grease from the module or coil if the same module is to be replaced. If a new module is to be installed, a package of silicone grease will be included with it. Spread the grease on the metal face of the module and on the cover where the module seats. This grease is necessary for module cooling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 394 1. Install the Ignition Control Module to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the Ignition Control Module to cover screws. Tighten Tighten the screws to 4 Nm (35 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 395 3. Install the ground strap (if the ground strap is not already installed). 4. Connect the Ignition Coil(s) electrical connector to the Ignition Control Module. Important: When installing the housing to the cover make sure the ground strap stays in place. 5. Install the housing to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 396 6. Install the housing to cover screws. Tighten Tighten the housing to cover screws 4 Nm (35 lb in). 7. Install the spark plug boots and the retainers to the housing (if the spark plug boot and retainer is not already installed). 8. Install the Ignition Coil and Electronic Ignition Control Module assembly to the engine while carefully aligning the spark boots to the spark plug terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 397 9. Install the ignition coil and the electronic ignition control module assembly to camshaft housing bolts after coating the threads with Sealant LOCTITE GM 12346004 or equivalent. Tighten Tighten the bolts to 22 Nm (16 lb ft). Important: The ICM cover bolts must be installed with isolator washers with the rubber side facing down. 10. Connect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 398 11. Install the fuel line retainer clip bolt. 12. Install the accelerator and cruise control cables into the hold down clip. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment Technical Service Bulletin # 98026 Date: 980818 US Version CAMPAIGN: INADVERTENT AIR BAG DEPLOYMENT # 98026 - (08/18/1998) NOTE: THE CANADIAN VERSION OF 98026 IS ALSO SHOWN. PRODUCT CAMPAIGNS 98026 AUGUST, 1998 SUBJECT: 98026 - INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODELS THE HIGHWAY SAFETY ACT, AS AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A RECALL CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A REASONABLE TIME AFTER THE CUSTOMER HAS TENDERED IT FOR REPAIR. A FAILURE TO REPAIR WITHIN SIXTY (60) DAYS AFTER TENDER OF A VEHICLE IS PRIMA FACIE EVIDENCE OF FAILURE TO REPAIR WITHIN A REASONABLE TIME. IF THE CONDITION IS NOT ADEQUATELY REPAIRED WITHIN A REASONABLE TIME, THE CUSTOMER MAY BE ENTITLED TO AN IDENTICAL OR REASONABLY EQUIVALENT VEHICLE AT NO CHARGE OR TO A REFUND OF THE PURCHASE PRICE LESS A REASONABLE ALLOWANCE FOR DEPRECIATION. TO AVOID HAVING TO PROVIDE THESE BURDENSOME REMEDIES, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH CUSTOMER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE COPY OF THE DIVISIONAL LETTER THAT IS BEING SENT TO CUSTOMERS, THE CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE (5) DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THEY ARE INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION. DEFECT INVOLVED GENERAL MOTORS HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 J CARS. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 408 INVOLVED ARE CERTAIN 1996-97 'J' MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTICE: DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) PRIOR TO BEGINNING CAMPAIGN REPAIRS. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM STATE MOTOR VEHICLE REGISTRATION RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF LAW IN SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION CUSTOMERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER SHOWN IN THIS BULLETIN ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALERS' POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE DIVISIONAL CUSTOMER LETTER ACCOMPANYING THIS BULLETIN. CAMPAIGN FOLLOW-UP CARDS SHOULD NOT BE USED FOR THIS PURPOSE, SINCE THE CUSTOMER MAY NOT AS YET HAVE RECEIVED THE NOTIFICATION LETTER. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, PLEASE TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 409 1. RETURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY". 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. 23. INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 410 EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. WHEN INSTALLING THE CAMPAIGN IDENTIFICATION LABEL, BE SURE TO PULL THE TAB TO ALLOW ADHESION OF THE CLEAR PROTECTIVE COVERING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM VISPAC INCORPORATED BY CALLING 1-800-269-5100 (MONDAY-FRIDAY, 8:00 A.M. TO 4:30 P.M. EST). ASK FOR ITEM NUMBER S-1015 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Canadian Version GM OF CANADA VERSION PRODUCT CAMPAIGNS 98026 AUGUST 1998 SUBJECT: CAMPAIGN 98026 INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE DEFECT INVOLVED GENERAL MOTORS OF CANADA LIMITED HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 411 VEHICLES INVOLVED INVOLVED ARE CERTAIN 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM THE INTER-PROVINCIAL RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF PROVINCIAL LAWS. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION ALL CUSTOMERS OF RECORD AT THE TIME OF CAMPAIGN RELEASE ARE SHOWN ON THE COMPUTER LISTING AND HAVE BEEN NOTIFIED BY FIRST CLASS MAIL FROM GENERAL MOTORS (SEE COPY OF CUSTOMER LETTER SHOWN IN THIS BULLETIN). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALER'S POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE CUSTOMER LETTER SHOWN IN THIS BULLETIN. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU MUST TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 412 IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). 1. TURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOUR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY" 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 413 23. INSTALL CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL." EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. INSERT CAMPAIGN NUMBER INSERT DEALER CODE EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM DGN BY CALLING 1-800-668-5539 (MONDAY-FRIDAY, 8:00 A.M. TO 5:00 P.M. EST). ASK FOR ITEM NUMBER GMP 91 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 414 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 415 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Air Bag Control Module: Recalls Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment Technical Service Bulletin # 98026 Date: 980818 US Version CAMPAIGN: INADVERTENT AIR BAG DEPLOYMENT # 98026 - (08/18/1998) NOTE: THE CANADIAN VERSION OF 98026 IS ALSO SHOWN. PRODUCT CAMPAIGNS 98026 AUGUST, 1998 SUBJECT: 98026 - INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODELS THE HIGHWAY SAFETY ACT, AS AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A RECALL CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A REASONABLE TIME AFTER THE CUSTOMER HAS TENDERED IT FOR REPAIR. A FAILURE TO REPAIR WITHIN SIXTY (60) DAYS AFTER TENDER OF A VEHICLE IS PRIMA FACIE EVIDENCE OF FAILURE TO REPAIR WITHIN A REASONABLE TIME. IF THE CONDITION IS NOT ADEQUATELY REPAIRED WITHIN A REASONABLE TIME, THE CUSTOMER MAY BE ENTITLED TO AN IDENTICAL OR REASONABLY EQUIVALENT VEHICLE AT NO CHARGE OR TO A REFUND OF THE PURCHASE PRICE LESS A REASONABLE ALLOWANCE FOR DEPRECIATION. TO AVOID HAVING TO PROVIDE THESE BURDENSOME REMEDIES, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH CUSTOMER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE COPY OF THE DIVISIONAL LETTER THAT IS BEING SENT TO CUSTOMERS, THE CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE (5) DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THEY ARE INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION. DEFECT INVOLVED GENERAL MOTORS HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 J CARS. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 425 INVOLVED ARE CERTAIN 1996-97 'J' MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTICE: DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) PRIOR TO BEGINNING CAMPAIGN REPAIRS. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM STATE MOTOR VEHICLE REGISTRATION RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF LAW IN SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION CUSTOMERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER SHOWN IN THIS BULLETIN ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALERS' POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE DIVISIONAL CUSTOMER LETTER ACCOMPANYING THIS BULLETIN. CAMPAIGN FOLLOW-UP CARDS SHOULD NOT BE USED FOR THIS PURPOSE, SINCE THE CUSTOMER MAY NOT AS YET HAVE RECEIVED THE NOTIFICATION LETTER. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, PLEASE TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 426 1. RETURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY". 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. 23. INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 427 EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. WHEN INSTALLING THE CAMPAIGN IDENTIFICATION LABEL, BE SURE TO PULL THE TAB TO ALLOW ADHESION OF THE CLEAR PROTECTIVE COVERING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM VISPAC INCORPORATED BY CALLING 1-800-269-5100 (MONDAY-FRIDAY, 8:00 A.M. TO 4:30 P.M. EST). ASK FOR ITEM NUMBER S-1015 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Canadian Version GM OF CANADA VERSION PRODUCT CAMPAIGNS 98026 AUGUST 1998 SUBJECT: CAMPAIGN 98026 INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE DEFECT INVOLVED GENERAL MOTORS OF CANADA LIMITED HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 428 VEHICLES INVOLVED INVOLVED ARE CERTAIN 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM THE INTER-PROVINCIAL RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF PROVINCIAL LAWS. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION ALL CUSTOMERS OF RECORD AT THE TIME OF CAMPAIGN RELEASE ARE SHOWN ON THE COMPUTER LISTING AND HAVE BEEN NOTIFIED BY FIRST CLASS MAIL FROM GENERAL MOTORS (SEE COPY OF CUSTOMER LETTER SHOWN IN THIS BULLETIN). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALER'S POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE CUSTOMER LETTER SHOWN IN THIS BULLETIN. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU MUST TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 429 IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). 1. TURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOUR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY" 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 430 23. INSTALL CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL." EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. INSERT CAMPAIGN NUMBER INSERT DEALER CODE EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM DGN BY CALLING 1-800-668-5539 (MONDAY-FRIDAY, 8:00 A.M. TO 5:00 P.M. EST). ASK FOR ITEM NUMBER GMP 91 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 431 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 432 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Air Bag Control Module: All Technical Service Bulletins Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 437 Air Bag Control Module: Specifications Inflatable Restraint Sensing and Diagnostic Module Fasteners 10.0 N.m (89 lb in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations > Page 440 Under RH Front Seat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 441 Sensing Diagnostic Module (SDM) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 442 Air Bag Control Module: Description and Operation CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the SDM horizontally on the mounting surface. ^ Point the arrow on the SDM toward the front of the vehicle. ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 443 The inflatable restraint sensing and diagnostic module (SDM) performs the following functions in the SIR system. ^ Energy Reserve-The SDM maintains 23 Volt Loop Reserve (23 VLR) energy supplies to provide deployment energy. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Frontal Crash Detection-The SDM monitors vehicle velocity changes to detect frontal crashes that are severe enough to warrant deployment. ^ Air Bag Deployment-During a frontal crash of sufficient force, the SDM will cause enough current to flow through the inflator modules to deploy the air bags. ^ Frontal Crash Recording-The SDM records information regarding the SIR system status during a frontal crash. ^ Malfunction Detection-The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a diagnostic trouble code. ^ Malfunction Diagnosis-The SDM displays SIR diagnostic trouble codes and system status information through the use of a scan tool. ^ Driver Notification-The SDM warns the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp. The SDM connects to the SIR wiring harness using a 12-way connector. The SDM harness connector uses a shorting bar across certain terminals in the contact area. Removal of the SDM Connector Position Assurance (CPA) or the harness connector itself will connect the AIR BAG warning lamp to ground through the shorting bar. The AIR BAG warning lamp will come ON steady with power applied to the SDM when either one of the following two conditions exist: ^ You remove the SDM CPA. ^ You disconnect the SDM harness connector. The SDM receives power whenever the ignition switch is at the RUN or START positions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions Air Bag Control Module: Service and Repair Important Preliminary Precautions CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the SDM horizontally on the mounting surface. ^ Point the arrow on the SDM toward the front of the vehicle. ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the Sensing and Diagnostic Module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming for instructions on how to disable the SIR system. See: Body and Frame/Interior Moulding / Trim/Dash Board / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of Significant soaking is detected, you MUST: ^ Remove all water ^ Repair the water damage ^ Replace the SDM harness connector ^ Replace the SDM Failure to follow these procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 446 Air Bag Control Module: Service and Repair Install or Connect INSTALL OR CONNECT 1. The inflatable restraint Sensing and Diagnostic Module (SDM) to the vehicle, make sure the arrow is pointing toward the front of the vehicle. 2. The SDM fasteners. TIGHTEN ^ Fasteners to 10 N.m (89 lb in.). 3. The electrical connector and the CPA. 4. The carpet and the passenger front carpet retainer. 5. The passenger front seat. ^ Enable the SIR system, refer to "Enabling the SIR System." See: Body and Frame/Interior Moulding / Trim/Dash Board / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 447 Air Bag Control Module: Service and Repair Remove or Disconnect REMOVE OR DISCONNECT ^ Disable the SIR system, Refer to "Disabling the SIR System." See: Body and Frame/Interior Moulding / Trim/Dash Board / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair 1. The passenger front seat. 2. The passenger front carpet retainer, then roll back the carpet. 3. The Connector Position Assurance (CPA) and the electrical connector. 4. The fasteners from the inflatable restraint sensing and diagnostic module. 5. The inflatable restraint Sensing and Diagnostic Module (SDM) from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 448 Air Bag Control Module: Service and Repair Repair of Mounting Studs and/or Bracket First Repair IMPORTANT ^ The following repair procedures should only he used in the event that the Sensing and Diagnostic Module (SDM) mounting fasteners are damaged to the extent that the SDM can no longer be properly mounted. FIRST REPAIR 1. Remove and discard the fastener. 2. Use a new fastener (P/N 10156138). 3. Torque the fastener to 10 N.m (89 lb in.). Second Repair IMPORTANT ^ The following repair procedures should only he used in the event that the Sensing and Diagnostic Module (SDM) mounting fasteners are damaged to the extent that the SDM can no longer be properly mounted. SECOND REPAIR 1. Remove and discard the fastener. 2. Use a larger fastener (P/N 10267482) with washer (P/N 11500305). 3. Torque the fastener to 15.0 N.m (134 lb in.). Use hand tools only to achieve fastener torque. This will prevent stripping of the replacement fastener. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Locations Convertible Top Switch: Locations Top Of Windshield Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations LH Front Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 461 Rear Window And Door Lock Switches Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations LH Front Door Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 465 Outside Mirror Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 469 Sunroof / Moonroof Switch: Service and Repair SUNROOF CONTROL SWITCH Remove 1. Using a small flat blade tool, disengage switch from headlining module 2. Connector from the switch, switch from vehicle. Install 1. Connector to the switch 2. Firmly push the switch into the headlining module to secure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations Fluid Level Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations > Page 475 LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 476 Brake Fluid Level Sensor/Switch: Description and Operation The master cylinder is equipped with a fluid level switch located in the side of the master cylinder reservoir. This switch will activate the red "BRAKE" light if a low fluid condition is detected. Once the fluid level is corrected the "BRAKE" light will go out. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 477 Brake Fluid Level Sensor/Switch: Service and Repair Fluid Level Switch REMOVE OR DISCONNECT 1. Electrical connector from fluid level switch. Proportioner Valves 2. Fluid level switch using needle nose pliers to compress switch locking tabs at inboard side of master cylinder reservoir. INSTALL OR CONNECT 1. Fluid level switch into master cylinder reservoir until locking tabs snap in place. 2. Electrical connector to fluid level switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 486 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 487 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 493 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 494 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Page 495 LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations Center Passenger Compartment, Above Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 500 LH I/P And Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set Wheel Speed Sensor: Customer Interest ABS Indicator Lamp On, DTC 21,22,32 or 33 Set File In Section: 5 - Brakes Bulletin No.: 63-50-15B Date: March, 1998 Subject: ABS Indicator Lamp ON, DTC 21, 22, 32 or 33 Set (Install Front ABS Wheel Speed Sensor Wiring Harness Connector Kit) Models: 1992-97 Buick Skylark 1991-96 Chevrolet Beretta, Corsica 1992-97 Chevrolet Cavalier 1992-97 Oldsmobile Achieva 1992-94 Pontiac Sunbird 1995-97 Pontiac Sunfire 1992-97 Pontiac Grand Am This bulletin is being revised to update parts and applicable model information. Please discard Corporate Bulletin Number 63-50-15A - (Section 5 - Brakes) Condition Some owners may comment that the ABS indicator lamp is "ON". Also, malfunction DTC 21, 22, 32 or 33 could set. Cause The right front and left front ABS wheel speed sensor wiring harness could be damaged and result in an open circuit. The wiring harness may be damaged approximately 4 inches (10 cm) back from the harness connector to the wheel speed sensor. This allows moisture to enter the harness causing corrosion and resulting in the open circuit. Correction A thorough inspection for corrosion and/or damage should be performed on suspect vehicles. It may be necessary to move the protective conduit away in order to inspect the wiring properly. If a failure occurs and damage is found, install the front ABS wheel speed sensor wiring harness connector kit(s). The kit includes instructions, splices, and "pigtail" connector. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set > Page 509 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time H2530 Right Side Use published H2531 Left Side Labor Operation Time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set Wheel Speed Sensor: All Technical Service Bulletins ABS Indicator Lamp On, DTC 21,22,32 or 33 Set File In Section: 5 - Brakes Bulletin No.: 63-50-15B Date: March, 1998 Subject: ABS Indicator Lamp ON, DTC 21, 22, 32 or 33 Set (Install Front ABS Wheel Speed Sensor Wiring Harness Connector Kit) Models: 1992-97 Buick Skylark 1991-96 Chevrolet Beretta, Corsica 1992-97 Chevrolet Cavalier 1992-97 Oldsmobile Achieva 1992-94 Pontiac Sunbird 1995-97 Pontiac Sunfire 1992-97 Pontiac Grand Am This bulletin is being revised to update parts and applicable model information. Please discard Corporate Bulletin Number 63-50-15A - (Section 5 - Brakes) Condition Some owners may comment that the ABS indicator lamp is "ON". Also, malfunction DTC 21, 22, 32 or 33 could set. Cause The right front and left front ABS wheel speed sensor wiring harness could be damaged and result in an open circuit. The wiring harness may be damaged approximately 4 inches (10 cm) back from the harness connector to the wheel speed sensor. This allows moisture to enter the harness causing corrosion and resulting in the open circuit. Correction A thorough inspection for corrosion and/or damage should be performed on suspect vehicles. It may be necessary to move the protective conduit away in order to inspect the wiring properly. If a failure occurs and damage is found, install the front ABS wheel speed sensor wiring harness connector kit(s). The kit includes instructions, splices, and "pigtail" connector. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set > Page 515 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time H2530 Right Side Use published H2531 Left Side Labor Operation Time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 516 Wheel Speed Sensor: Specifications Front Wheel Sensor Bolt 107 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead LH Front Wheel (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 519 LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 520 Front Wheel Speed Sensor Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 521 LH Front Wheel (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 522 Rear Axle Harness Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service Precautions > Technician Safety Information Wheel Speed Sensor: Technician Safety Information WARNING: Raise and support vehicle on suitable hoist . Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service Precautions > Technician Safety Information > Page 525 Wheel Speed Sensor: Vehicle Damage Warnings CAUTION: ^ The front wheel speed sensor wiring is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. ^ The front wheel speed sensor wiring is not repairable in the control arm section of the wiring harness. This section of the wiring harness must be replaced with the appropriate wiring harness service kit "pigtail." The splice must be located within the main branch of the engine harness. Do not attempt to solder, splice, or crimp this section of the wiring harnesses as eventual failure will likely result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring Wheel Speed Sensor: Description and Operation Toothed Ring The toothed ring mentioned above is pressed onto the outer Constant Velocity (CV) joint. Each ring contains 48 equally spaced teeth. Care should be exercised during service procedures to avoid contact with this ring, as damage to one or more teeth may result. If the ring is damaged, the outer CV joint must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 528 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensors The front wheel speed sensors are of a variable reluctance type. Each sensor is attached to the knuckle assembly in close proximity to a toothed ring. An AC voltage is generated when the toothed ring passes by the sensor. The magnitude and frequency are proportional to the speed of the wheel and both will increase with increasing speed. The sensor is not repairable, nor is the air gap adjustable. However, air gap should be between 0.5 mm (0.020 inches) and 1.7 mm (0.070 inches). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 529 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Wiring The front wheel speed sensor wiring is constructed of highly flexible twisted pair wiring. This wiring exists because the front wheel speed sensor wiring circuits must connect to the suspension of the vehicle, thus the wiring in this area is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. For this reason, THE FRONT WHEEL SPEED SENSOR WIRING IS NOT REPAIRABLE IN THE CONTROL ARM SECTION OF THE WIRING HARNESS. THIS SECTION OF THE WIRING HARNESS MUST BE REPLACED WITH THE APPROPRIATE WIRING HARNESS SERVICE KIT "PIGTAIL." DO NOT ATTEMPT TO SOLDER, SPLICE, OR CRIMP THIS SECTION OF THE WIRING HARNESSES AS EVENTUAL FAILURE WILL LIKELY RESULT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 530 Wheel Speed Sensor: Description and Operation Rear Wheel Speed Sensors and Rings The rear wheel speed sensors operate in the same manner as the front wheel speed sensors. Refer to Front Wheel Speed Sensors. The wheel speed sensor and toothed ring are contained within the dust cap of the integral rear wheel bearing. This allows for improved environmental protection and easier assembly. The sensor and toothed ring are not repairable and no provision for air gap adjustment exists. If a rear wheel speed sensor fails, the entire integral bearing and speed sensor assembly must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 531 Wheel Speed Sensor: Description and Operation Rear Axle Harness The rear axle harness is constructed of twisted pair wiring. Because the rear axle harness is not subjected to the same motion as the front wheel speed sensor wiring, the rear axle harness can be serviced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Front Wheel Speed Sensor Removal REMOVE OR DISCONNECT 1. Raise and support vehicle on suitable hoist. 2. Front sensor electrical connector. 3. Retaining bolt. 4. Front wheel speed sensor. If sensor will not slide out of knuckle, remove brake rotor and use a blunt punch or equivalent tool to push sensor from back side of knuckle. If sensor locating pin breaks off and remains in knuckle during removal, proceed as follows. a. Remove brake rotor and remove broken pin using a blunt punch. b. Clean hole using sand paper wrapped around a screwdriver or other suitable tool. Never attempt to enlarge the hole. INSTALL OR CONNECT 1. Front wheel speed sensor on mounting bracket. Make sure front wheel speed sensor is properly aligned and lays flat against bosses on knuckle. 2. Retaining bolt. Tighten retaining bolt to 12 Nm (107 inch lbs.). 3. Front sensor electrical connector to front wheel speed sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 534 Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Wiring Right Front Wheel Speed Sensor Harness Left Front Wheel Speed Sensor Harness CAUTION: ^ The front wheel speed sensor wiring is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. ^ The front wheel speed sensor wiring is not repairable in the control arm section of the wiring harness. This section of the wiring harness must be replaced with the appropriate wiring harness service kit "pigtail." The splice must be located within the main branch of the engine harness. Do not attempt to solder, splice, or crimp this section of the wiring harnesses as eventual failure will likely result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 535 REMOVE OR DISCONNECT 1. Connector from wheel speed sensor. 2. Harness attaching clips for control arm and splash shield. 3. Lower vehicle. 4. Harness attaching clips from strut tower. 5. Cut wheel speed sensor wiring circuits within main engine harness. 6. Strip insulation on engine harness leads and new wheel speed sensor harness leads. INSTALL OR CONNECT 1. Splice sleeve provided in jumper harness kit over each engine harness leads. 2. New wheel speed sensor harness leads to engine harness leads (matching color) and crimp connections. 3. Heat shrink tube lightly to seal. 4. Harness attaching clip to strut tower. 5. Raise and support vehicle on suitable hoist. 6. Harness attaching clips to control arm and splash shield. 7. Connector to wheel speed sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 536 Wheel Speed Sensor: Service and Repair Rear Axle Harness Rear Axle Harness Removal WARNING: Raise and support vehicle on suitable hoist. REMOVE OR DISCONNECT 1. Two rear sensor electrical connectors from rear wheel bearing and speed sensor assemblies. 2. Rear axle harness electrical connector from body to ABS and fuel sender connector. 3. Wire harness from restraints. 4. Rear speed sensor wiring harness from vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 537 INSTALL OR CONNECT 1. Rear speed sensor wiring harness in vehicle. 2. Wire harness restraints. 3. Rear ABS axle harness electrical connector to body to ABS and fuel sender connector. 4. Two rear sensor electrical connectors to rear wheel bearing and speed sensor assemblies. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations RH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 542 Coolant Level Sensor: Description and Operation This vehicle uses a "Low Coolant" warning switch. This switch is located in the coolant surge tank. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 543 Coolant Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Drain and recover the coolant. 2. Coolant hoses from radiator surge tank. 3. Low coolant connector. 4. Radiator surge tank bolt and tank. 5. Low coolant switch from tank. INSTALLATION PROCEDURE 1. Low coolant switch to tank. 2. Place tank in vehicle. Tighten bolt to 10 Nm (89 inch lbs.). 3. Coolant hoses to radiator surge tank. 4. Low coolant connector. 5. Fill cooling system at radiator surge tank to appropriate full mark. 6. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Left Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 549 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 550 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperatures produce a high resistance (100,000 ohms at -40°C/-40°F), while high temperatures cause low resistance (70 ohms at 130°C/266°F). The Powertrain Control Module (PCM) uses this signal to determine the engine coolant temperature. OPERATION The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the ECT sensor's resistance is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table will lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 551 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection A scan tool displays the engine temperature in degrees Celsius. After the engine is started, the temperature should rise steadily to about 90°C (194°F) then stabilize when the thermostat opens. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 552 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal Procedure Notice: Care must be taken when handling an Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. Installation Procedure 1. Coat only the threads with sealer. 2. Install the ECT sensor in the engine, fully driven, seated and not stripped. 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 557 Brake Switch (Cruise Control): Description and Operation The cruise control release switch and stoplamp switch assemblies are used to disengage the cruise control system. A release switch and stoplamp switch assembly mounted on the brake pedal bracket disengages the system electrically when the brake pedal is depressed. This is done by activating the brake cut-out input to the cruise control module assembly. The speed of the vehicle at brake actuation will be stored in the memory of the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 558 Brake Switch (Cruise Control): Adjustments The release switch assembly and the stoplamp switch assembly cannot be adjusted until after the brake booster pushrod is assembled to the brake pedal assembly. The cruise control release switch and the stoplamp switch are adjusted together. Incorrect adjustment could cause the cruise control system to not work properly. Adjust 1. Press brake pedal assembly and insert switch assembly and stoplamp switch assembly into retainers until fully seated. 2. Slowly release brake pedal assembly back to its fully retracted position. The release switch assembly will move within retainers to their adjusted" position. Measure The following brake pedal assembly travel distances can be used to check for properly adjusted release switch assembly and stoplamp switch assembly. Release switch assembly and stoplamp switch assembly contacts must be open at 3.5 to 12.5 mm (1/8 to 1/2 inch) brake pedal assembly travel, measured at the centerline of The brake pedal assembly pad. Nominal actuation of the stoplamp switch assembly contacts is about 4.5 mm (3/16 inch) after cruise control switch assembly contacts close. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 559 Brake Switch (Cruise Control): Service and Repair Cruise Control Switches Remove or Disconnect 1. Left sound insulator. 2. Wiring harness connector(s). 3. Pull switch rearward to remove from retainer in bracket. Install or Connect 1. Retainer into bracket (from forward side). 2. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Audible "clicks" can be heard as ribbed portion of switch is pushed forward through the retainer. 3. Wiring harness connector(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 560 Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. Switch will be moved in retainer providing adjustment. b. Release brake or clutch pedal and repeat Step A to assure that switch is properly adjusted. 4. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations LH Lower I/P LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 564 Clutch Switch: Service and Repair Cruise Control Switches Remove or Disconnect 1. Left sound insulator. 2. Wiring harness connector(s). 3. Pull switch rearward to remove from retainer in bracket. Install or Connect 1. Retainer into bracket (from forward side). 2. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Audible "clicks" can be heard as ribbed portion of switch is pushed forward through the retainer. 3. Wiring harness connector(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 565 Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. Switch will be moved in retainer providing adjustment. b. Release brake or clutch pedal and repeat Step A to assure that switch is properly adjusted. 4. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Cruise Control Switch Cruise Control Switch: Description and Operation Cruise Control Switch The Off/On/Resume/Accel Switch has three positions.This switch turns the cruise control system On and Off, and also returns cruise control operation to the last speed setting when MOMENTARILY moved towards the R/A position after braking. If the slider is held in the R/A position for more than one second, the system reverts to the Accel mode. To accelerate the vehicle, move the slider switch to the R/A position and hold it there until the vehicle reaches the desired increased speed. When the slider switch is released, the speed the vehicle accelerated to becomes the new cruise speed. In order to use the Accel mode, the cruise Off/On/Resume/Accel switch must be in the "ON" position and the vehicle must be above the low speed lockout which is approximately 40 km/h (25 mph). The slide switch may also be used to "tap-up" vehicle speed. In order to do this, the cruise must be engaged and operating. "Tapping-up" is done by quickly pressing the slide switch toward the R/A position and quickly releasing it, or "tap" the lever. Do not hold the lever in the R/A position or the system will revert to the Accel mode. "Tap-up" is a function in which cruise speed can be increased by 0.62 km/h (1 mph) increments (one tap = 1 mph increase) IMPORTANT Unless the SET button has been previously set in the current ignition cycle, R/A will not function. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Cruise Control Switch > Page 570 Cruise Control Switch: Description and Operation Set/Coast Switch The cruise control Set/Coast Switch (located in the end of the turn signal lever) has two positions "Normal" and "Depressed." ^ The Set Position: With the button switch depressed and then released (vehicle speed must exceed the low speed lockout point, and the Off/On/Resume/Accel Switch must be in the ON position) the cruise speed will be set at the particular speed the vehicle was at when the button was released. Car cruise speed will be within 0.62 km/h (1 mph) of the actual speed when engaged and after the speed has stabilized. (NOTE: It is no longer possible to set the cruise with the RESUME button). The system will cruise until either the Off/On/Resume/Accel Switch is moved to OFF, the ignition switch is turned off, and/or the Set/Coast Button is pushed in fully and held. Pushing the brake pedal (or clutch pedal) releases the cruise but not the resume capability. ^ The Coast Position: With the button switch fully depressed, the driver can raise or lower his control speed. To increase control speed, the driver would accelerate to a new speed, fully depress the switch (controller releases previously set speed) and release the button. Upon releasing the button a new speed is set. An increased control speed can also be more easily set by the Off/On/Resume/Accel Switch as previously described. To decrease cruise speed, the button switch is held in (depressed position) disengaging the cruise system, and allowing the throttle to return to the idle position. When the vehicle has slowed to the desired lower cruise speed, releasing the switch will re-engage the system at the lower speed. ^ The "Tap-Down" Position: In order to do this the cruise must be engaged and operating. "Tapping-down" is done by quickly pressing the Set/Coast Button to the depressed position and quickly releasing it, or "tap" the button. Do not hold the button in the depressed position or the system will revert to the "coast" mode. "Tap-down" is a function in which cruise speed can be decreased by 0.62 km/h (1 mph) increments (one tap = 1 mph decrease). The system can "tap-down" until it reaches the low speed lockout 40 kin/h (25 mph), after this cruise will not operate. The accelerator may be depressed at any time to override the cruise system. Release of the accelerator will return the vehicle to the previously set cruise speed. NOTICE: To keep the vehicle under control, and to prevent possible vehicle damaged, it is not advisable to use the Cruise Control on slippery roads. It is not recommended to use the cruise control in conditions such as on winding roads or in traffic of heavy or varying volume. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Brake and Clutch Pedal Switches Cruise Control Switch: Service and Repair Brake and Clutch Pedal Switches Description Description Remove or Disconnect 1. Left sound insulator. 2. Pull switch rearward to remove from retainer in bracket 3. Wiring Harness connectors. Install or Connect 1. Wiring harness to switch. 2. Retainer into bracket (from forward side). 3. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. b. Switch will be moved in retainer providing adjustment. c. Release brake or clutch pedal and repeat Step "a" to assure that switch is properly adjusted. 4. Wiring harness connector(s). 5. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Brake and Clutch Pedal Switches > Page 573 Cruise Control Switch: Service and Repair Engagement Switch The cruise control engagement switch is part of the turn signal lever assembly and is not serviceable by itself. The turn signal lever and cruise control switch must be replaced as an assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair Remove or Disconnect 1. Negative battery cable. 2. I/P trim plate. 3. Control assembly screws and pull control assembly away from the I/P. 4. Blower switch knob. 5. Electrical connection. 6. Blower switch retaining screws and blower switch. Install or Connect 1. Blower switch and retaining screws. 2. Electrical connection. 3. Blower switch knob. 4. Control assembly and retaining screws. 5. I/P trim plate. 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Pressure Transducer .................................................................................................................... ....................................................... 5 N.m (44 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 588 RH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 589 Refrigerant Pressure Sensor / Switch: Description and Operation PURPOSE A/C Refrigerant Pressure Sensor The Air Conditioning (A/C) refrigerant pressure sensor provides a signal to the Powertrain Control Module (PCM) which indicates varying high side refrigerant pressure between approximately 0 psi and 450 psi. OPERATION The PCM uses this input in order to determine the A/C compressor load on the engine in order to help control idle speed with the IAC valve. The A/C refrigerant pressure sensor electrical circuit consists of a 5 volt reference line and a ground line, both provided by the PCM, and a signal line to the PCM. The signal is a voltage that varies from approximately 0.1 volt at 0 psi, to 4.9 volts at 450 psi or more. A problem in the A/C refrigerant pressure circuits or sensor may set a DTC P0530 and will make the A/C compressor inoperative. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 590 Refrigerant Pressure Sensor / Switch: Testing and Inspection A scan tool displays A/C refrigerant pressure in psi. The sensor's range and corresponding display should be in the range of 0 to 450 psi. A sensor or circuit problem should set DTC P0530. A poor ground at the sensor will result in a fixed high pressure value on the scan tool display. Refer to A/C Compressor Clutch Control Diagnosis 2.4L for further diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Pressure Sensor Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Sensor The A/C system has a pressure sensor mounted on the compressor/condenser hose assembly near the condenser connection. The sensor performs both low and high pressure cut-out functions through an input to the PCM. No compressor mounted switches are used. The sensor is mounted on a service fitting and can be replaced without discharging the A/C system. Remove or Disconnect 1. Negative battery cable. 2. Electrical connection at the sensor. 3. Pressure sensor and discard the O-ring seal. ^ The sensor is mounted on a service fitting; do not discharge the system. Install or Connect 1. New O-ring seal lubricated in clean 525 viscosity refrigerant oil. 2. Pressure sensor. 3. Electrical connection at the sensor. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Pressure Sensor > Page 593 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Sensor Schrader Valve The Schrader valve is located under the A/C pressure sensor in the compressor discharge hose. Tools Required: J 24182-2A Valve Core Remover/Installer J 39500 R- 134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Harness from pressure sensor. 3. Pressure sensor from fitting. 4. Schrader valve from fitting. Install or Connect 1. New valve to fitting. 2. Pressure sensor to fitting. 3. Harness to pressure sensor. 4. Recharge A/C system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead > Page 601 LH I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch Connector RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch Connector > Page 606 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 611 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 612 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 613 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 614 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 615 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 616 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 625 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 626 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 632 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 633 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Page 634 LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Back Up Lamp Switch LH Rear Of Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Back Up Lamp Switch > Page 640 Backup Lamp Switch: Locations Wire Harness to TCC and Neutral Start and Backup Light SW LH Front Of Engine/Transaxle LH Engine/Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 641 Backup Lamp Switch: Service and Repair NOTICE: When removing or installing the backup light switch, DO NOT use a open end wrench. Use only a socket to avoid damage to the switch assembly. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Backup lamp connector. 3. Backup light switch assembly. INSTALL OR CONNECT 1. Backup light switch assembly. - Use pipe sealant GM P/N 1052080 or equivalent. Tighten Backup light switch to 33 N.m (24 lb. ft.). 2. Backup light connector. 3. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 645 Brake Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 646 Brake Light Switch: Service and Repair Stop Light Switch REMOVE OR DISCONNECT 1. Driver side sound insulator. 2. Electrical connection. 3. Brake switch from retainer by grasping and pulling toward rear of vehicle. INSTALL OR CONNECT 1. Insert stop lamp switch into retainer until switch body seats on retainer. 2. Pull brake pedal upward against internal pedal stop. Switch will be moved in retainer providing proper adjustment. Proper switch adjustment is achieved when no clicks are heard when the pedal is pulled upward and the brake lights do not stay on without brake application. 3. Electrical connection. 4. Driver side sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch Connector RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch Connector > Page 651 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 655 Folding Top Bypass Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 656 Fog/Driving Lamp Switch: Description and Operation The fog lamp switch is located in the dimmer switch assembly. To turn on the fog lamps the ignition switch must be in the "RUN" position and the fog lamp switch must be in the "ON" position with the high beams off. When the fog lamps are turned on (head and park lamps off) the front and rear marker lamps, park lamps, tail lamps, license lamp and instrument panel lamps must also be on. When the high beam head lamps are selected, the fog lamps are turned off. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 660 Hazard Warning Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Headlamp Switch Lead Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Headlamp Switch Lead > Page 665 LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 666 Headlamp Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Center Of Steering Wheel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 673 Turn Signal Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 680 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 681 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 682 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 683 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 684 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 686 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 687 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 688 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 689 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 690 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 691 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 692 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 693 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 694 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 695 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 701 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 704 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 705 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 714 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 715 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 718 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 719 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 720 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 722 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 723 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 725 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 726 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 727 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 728 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 729 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 731 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 732 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 733 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 734 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 735 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 736 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 737 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 739 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 740 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 742 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 743 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 744 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 745 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 746 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 747 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 748 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 749 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 750 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Left Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 755 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 756 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperatures produce a high resistance (100,000 ohms at -40°C/-40°F), while high temperatures cause low resistance (70 ohms at 130°C/266°F). The Powertrain Control Module (PCM) uses this signal to determine the engine coolant temperature. OPERATION The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the ECT sensor's resistance is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table will lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 757 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection A scan tool displays the engine temperature in degrees Celsius. After the engine is started, the temperature should rise steadily to about 90°C (194°F) then stabilize when the thermostat opens. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 758 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal Procedure Notice: Care must be taken when handling an Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. Installation Procedure 1. Coat only the threads with sealer. 2. Install the ECT sensor in the engine, fully driven, seated and not stripped. 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 762 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 765 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 766 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 768 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 770 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 773 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 775 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 776 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 778 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 779 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 780 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 782 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 783 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 784 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 786 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 789 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 790 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 791 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 793 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 796 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 797 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 802 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 803 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 804 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 805 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 806 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 807 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 808 Fuel Level Sensor: Description and Operation Purpose The Fuel Level Sensor is an important input to the Control Module for the enhanced evaporative system diagnostic. The fuel level information is needed for the Control Module to know the volume of the fuel tank. The fuel level affects the rate of charge in the air pressure in the EVAP system. Several of the Enhanced Evaporative System diagnostic sub-tests are dependent upon the correct fuel level information. Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gage. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 809 Fuel Level Sensor: Testing and Inspection The PCM uses the fuel level input to determine the expected amount of vapor pressure or vacuum to expect within the fuel tank. The scan tool can displays fuel level in percent for diagnostic purposes. A DTC P0460 will be set if the PCM does not see a change in the fuel level after a certain time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 810 Fuel Level Sensor: Service and Repair Removal Procedure 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Drain fuel tank. Refer to Draining Fuel Tank. 3. Remove the fuel tank. Refer to Fuel Tank. 4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. Installation Procedure 1. Fuel level sensor to modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. Refer to Fuel Sender Assembly. 4. Install the fuel tank. Refer to Fuel Tank. 5. Refill tank. 6. Inspect for fuel leaks through the following steps: 6.1. Turn the ignition to the ON position for two seconds 6.2. Turn the ignition to the OFF position for ten seconds. 6.3. Turn the ignition to the ON position 6.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Description The Fuel Tank Pressure sensor is a 3 wire strain gauge sensor much like that of the common MAP sensor. However, this sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. A three wire electrical harness connects it to the Control Module. The Control Module supplies a 5 volt reference voltage and ground to the sensor. The sensor sends a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measures 1.3 to 1.7 volts. Operation When the air pressure in the tank is 4.5 inches H2O (1.25 kPa), the sensor output voltage should measure 0.5 plus/minus 0.2 volts. When there is neither a vacuum or a pressure in the tank, the sensor voltage should be at 1.5 volts at 14 inches H2O (-3.75 kPa) the sensor output voltage should be 4.5 volts plus/minus 0.2 volts. When energized, the evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP canister to the engine. The normally closed valve is pulse width modulated by the Control Module in order to precisely control the vapor flow. The valve opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in the fuel tank and then closed in order to seal the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 814 Fuel Tank Pressure Sensor: Testing and Inspection The scan tool displays fuel tank pressure in volts and inches of water per second. The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 815 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Perform Fuel Pressure Relief Procedure. 3. Drain fuel tank. 4. Remove the fuel tank. Refer to Fuel Tank. 5. Remove the electrical connector from the fuel tank vapor pressure sensor. 6. Remove the fuel tank vapor pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank vapor pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank vapor pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 821 LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 824 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 825 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 826 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 827 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Intake Air Temperature Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 831 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 832 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 834 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 835 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 837 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 838 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 839 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 842 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 845 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 848 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 849 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 856 Intake Air Temperature Sensor: Description and Operation OPERATION The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the Engine Coolant Temperature (ECT) sensor. Low temperature produces a high resistance (100,000 ohms at -40°C / -40°F) while high temperature causes low resistance (70 ohms at 130°C / 266°F). The Powertrain Control Module (PCM) supplies a 5 volt signal to the sensor through a resistor in the PCM and measures the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A failure in the IAT sensor circuit should set either a Diagnostic Trouble Code (DTC) P0112 or P0113. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 857 Intake Air Temperature Sensor: Testing and Inspection A scan tool displays the temperature of the air entering the engine, which should be close to ambient air temperature when engine is cold, and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 858 Intake Air Temperature Sensor: Service and Repair Removal Procedure The Intake Air Temperature (IAT) sensor is installed in the air induction flex tube. Care must be taken when handling a IAT sensor to avoid damage. 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. Installation Procedure 1. Install the IAT sensor into air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls - Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 863 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 866 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 867 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 870 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 871 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 872 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 874 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 875 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 876 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 877 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 878 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 880 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 881 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 882 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 883 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 884 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 885 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 891 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 892 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 893 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 894 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 895 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 896 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 897 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 898 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 900 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 901 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 902 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Attaching Screw ............................................................................................................. .................................................... 6.5 Nm (5.7 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 906 Manifold Pressure/Vacuum Sensor: Locations Front Right Of Engine Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 907 Manifold Pressure/Vacuum Sensor: Description and Operation MAP Sensor DESCRIPTION The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. OPERATION The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gage. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 908 Manifold Pressure/Vacuum Sensor: Testing and Inspection A scan tool displays manifold pressure in kPa and MAP sensor signal voltage. Low pressure (high vacuum) displays a low voltage while a high pressure (low vacuum) displays a high voltage. A failure in the MAP sensor circuit should set a DTC P0107 or P0108 and using the applicable table will lead to the cause of the problem. A DTC P0108 may be set if misfire or a rough or unstable idle exists. A DTC P0105 will set for a MAP sensor that intermittently sends a zero voltage signal to the PCM. MAP Sensor Output Check 2.4L can also be used to check the MAP sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 909 Manifold Pressure/Vacuum Sensor: Service and Repair Removal Procedure 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor attaching screws (1). 4. Remove the MAP sensor vacuum hose (2). Installation Procedure 1. Connect the vacuum hose (2). 2. Install the MAP sensor attaching screw (1). Tighten the attaching screw to 6.5 Nm (5.7 lb. in.). 3. Connect the MAP sensor electrical connector. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems Oxygen Sensor: Technical Service Bulletins Oxygen Sensor - Locations in Various Exhaust Systems File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 917 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 918 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 919 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to misidentification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 920 Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 41 Nm (30 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Technical Service Bulletin Update File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 923 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 924 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 925 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to mis-identification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 926 Component Location Views Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 927 LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 928 LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 929 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 930 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 933 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 934 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 935 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 937 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 941 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 943 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 944 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 946 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 947 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 948 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 949 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 950 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 954 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 957 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 958 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 959 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 960 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 963 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 964 Post - Converter Heated Oxygen Sensor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) Oxygen Sensor: Description and Operation Oxygen Sensor (O2S 1) Purpose The Oxygen Sensor (02S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately .1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). This voltage can be measured with a scan tool. Operation By monitoring the voltage output of the 02S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low 02S 1 voltage = rich command - Rich mixture - high 02S 1 voltage = lean command The 02S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 967 Oxygen Sensor: Description and Operation Heated Oxygen Sensor 2 (HO2S 2) Catalyst Monitor The Rear Heated Oxygen Sensor (HO2S 2)is used to monitor the oxygen storage capability of the catalytic converter. Similar to the 02S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to .9 volt (low oxygen - rich mixture). Unlike the 02S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 968 Oxygen Sensor: Description and Operation Catalyst Monitor Diagnostic Operation The OBD II catalyst monitor diagnostic measures oxygen storage capacity. In order to do this, the heated sensors are installed before and after the Three-Way Catalyst (TWC). Voltage variations between the sensors allow the control module to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalyst's capacity to store and release oxygen generally degrades. The OBD II catalyst monitor diagnostic is based on an correlation between conversion efficiency and oxygen storage capacity. A good catalyst (e.g. 95% hydrocarbon conversion efficiency) shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor (HO2S). A degraded catalyst (65% hydrocarbon conversion) shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S 2 is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst; low oxygen storage capacity indicates a failing catalyst. The TWC, HO2S 2, and HO2S 3 must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the Post-Catalyst HO2S 3 Outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S Contamination ^ Alternate fuels Exhaust system leaks may cause the following results: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevents the TWC diagnostic from functioning properly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 969 Oxygen Sensor: Description and Operation HO2S Heater The oxygen sensor heaters are required by catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) Oxygen Sensor: Testing and Inspection Oxygen Sensor (O2S 1) A scan tool has several parameters that indicate the state of the exhaust gases: O2S 1 voltage, Short Term (S. T.) fuel trim, and Long Term (L. T.) fuel trim. A problem in the O2S 1 circuit should set a DTC P0134 (open circuit), DTC P0131 (lean exhaust indication), or DTC P0132 (rich exhaust indication). A faulty or lazy sensor will set a DTC P0133 (slow response) or a DTC P1133 (insufficient switching). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) > Page 972 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (H02S 2) The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when the activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement Oxygen Sensor: Service and Repair Oxygen (O2S) Sensor Replacement O2S Service Removal Procedure Notice: The 02S 1 uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the oxygen sensor. Important: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the 02S 1. Important: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). Notice: Excessive force may damage the threads in the exhaust pipe. 1. Turn the ignition switch OFF. 2. Disconnect the Oxygen Sensor 1 electrical connector (1). 3. Carefully remove the oxygen sensor (2). Installation Procedure Important: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the oxygen sensor (2) with anti-seize compound, if necessary. 2. Install the Oxygen Sensor (2). Tighten the 02S 1 41 Nm (30 lb. ft.). 3. Connect the Oxygen Sensor 1 electrical connector (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement > Page 975 Oxygen Sensor: Service and Repair Catalyst Monitor (HO2S) Oxygen Sensors Removal Procedure Notice: The HO2S 2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the rear heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the rear heated oxygen sensor. Important: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the O2S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. Notice: Excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. Installation Procedure Important: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb. ft.). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 979 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 982 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 983 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 984 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 985 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 986 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 987 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 988 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 989 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 990 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 992 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 993 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 995 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 996 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 997 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 998 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 999 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1013 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1014 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1015 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1024 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1025 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1031 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1032 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 1044 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1045 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1046 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1047 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 1050 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 1051 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 1052 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits Vehicle Speed Sensor: Technical Service Bulletins Instruments - New Diagnostic Tables For VSS Circuits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-81-32 Date: May, 1997 SERVICE MANUAL UPDATE Subject: Section 8A - Electrical Diagnosis - New Diagnostic Tables for Vehicle Speed Sensor Signal Circuit Models: 1996-97 Buick Skylark 1996 Chevrolet Beretta, Corsica 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1997 Oldsmobile Cutlass 1996-97 Pontiac Grand Am, Sunfire This bulletin is being issued to add new diagnostic tables to Section 8A of the Service Manual. The tables included describe the diagnostic procedures for the diagnosis of the Vehicle Speed Sensor signal circuit from the Powertrain Control Module (PCM) to auxiliary devices. Please insert the included diagnostic tables into the Electrical Diagnosis Instrument Cluster section (Cell 80 J/L/N cars; Cell 81 L/N cars) of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1057 8A - 1 - 1 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1058 8A - 1 - 2 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1059 8A - 1 - 3 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1060 8A - 1 - 4 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1061 8A - 1 - 5 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1062 8A - 1 - 6 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1063 8A - 1 - 7 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1064 8A - 1 - 8 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1065 8A - 1 - 9 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1066 8A - 1 - 10 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1067 8A - 1 - 11 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1068 8A - 1 - 12 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1069 8A - 1 - 13 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1070 8A - 1 - 14 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1071 8A - 1 - 15 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1072 8A - 1 - 16 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1073 8A - 1 - 17 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1074 8A - 1 - 18 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1075 8A - 1 - 19 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1076 8A - 1 - 20 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1077 8A - 1 - 21 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1078 8A - 1 - 22 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1079 8A - 1 - 23 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1080 8A - 1 - 24 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1081 8A - 1 - 25 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1082 8A - 1 - 26 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1083 8A - 1 - 27 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 1084 8A - 1 - 28 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 1085 Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1093 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1098 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1114 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1115 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1116 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1117 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1118 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1119 Vehicle Speed Sensor: Description and Operation Description The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Trans. for more information. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1120 Vehicle Speed Sensor: Testing and Inspection A scan tool km/h MPH display should closely match the speedometer reading with drive wheels turning. A malfunction in the Vehicle Speed Sensor ( VSS) circuit will set a DTC P0502. Refer to Automatic Trans. if a problem exists with the VSS. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 Vehicle Speed Sensor: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Vehicle speed sensor (VSS) lead from transaxle. 3. Speed sensor housing bolts and housing. 4. Speed sensor housing O-ring. INSTALL OR CONNECT 1. Speed sensor housing O-ring. - Lubricate with DEXRON III. 2. Speed sensor housing and bolts. 3. VSS lead to transaxle. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 1123 Vehicle Speed Sensor: Service and Repair Isuzu 76mm REMOVE OR DISCONNECT 1. Vehicle speed sensor (VSS) lead from the transaxle. 2. Bolt/screw and retainer. 3. VSS assembly. 4. O-ring. INSTALL OR CONNECT 1. VSS assembly with New O-ring. - Lubricate O-ring with Synchromesh Transaxle Fluid GM P/N 12345349. 2. VSS assembly. 3. Retainer and bolt/screw. Tighten Vehicle Speed Sensor to 9 N.m (80 lb. in.). 4. VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 1124 Vehicle Speed Sensor: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Raise and support-vehicle. 2. Electrical connector. 3. Bolt holding speed sensor. 4. Vehicle speed sensor from case extension. 5. O-ring from vehicle speed sensor. INSTALL OR CONNECT 1. O-ring onto vehicle speed sensor. 2. Vehicle speed sensor into case extension. 3. Bolt. Tighten Bolt to 11 N.m (97 lb. in.). 4. Electrical connector. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1130 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1131 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1132 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1133 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1134 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1135 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1136 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1137 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1138 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1139 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1140 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1141 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1142 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1143 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1144 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1147 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1167 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1201 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1202 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1203 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1208 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1209 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1216 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1218 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1219 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1243 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1244 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1248 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1282 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1283 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1293 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1294 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1295 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1305 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1306 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1307 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1313 Ignition Switch Lock Cylinder: Service and Repair Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 1318 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 1321 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 1322 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1325 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1326 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1327 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1328 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1329 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1330 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1331 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1332 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1333 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1334 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1356 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1357 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Impact Sensor: Recalls Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Impact Sensor: All Technical Service Bulletins Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 1372 Front Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Impact Sensor: Service and Repair Front End Discriminating Sensor The presence of an inflatable restraint front end discriminating sensor enhances the SIR system performance. Use of the inflatable restraint front end discriminating sensor provides timely deployment of the air bags during some crashes. Although this is a mechanical sensor, it is not a part of the deployment loop but instead only provides an input signal to the inflatable restraint sensing and diagnostic module. Caution should be used to ensure proper location of sensors to the mounting brackets. The keying of the sensor to the wiring harness connectors must not be modified for any reason. CAUTION: During service procedures, be very careful when handling a sensor. Never strike or jar a sensor. Under some circumstances, it could cause deployment and result in personal injury or improper operation of the Supplemental Inflatable Restraint (SIR) system. All sensors and mounting bracket bolts must be carefully torqued to assure proper operation. Never power up the SIR system when any sensor is not rigidly attached to vehicle, since the sensor could be activated when not attached and could result in deployment. REMOVE OR DISCONNECT ^ Disable the SIR system. Refer to "Disabling the SIR System." See: Body and Frame/Interior Moulding / Trim/Dash Board / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair 1. The Connector Position Assurance (CPA) and the electrical connector. 2. The sensor mounting fasteners. 3. The sensor from the vehicle. IMPORTANT ^ The following repair procedures should only be used in the event that the sensor mounting holes and/or fasteners are damaged to the extent that the sensor can no longer be properly mounted. 1. Remove and discard the fastener. 2. Chisel off the damaged weld nut. 3. Condition the front end lower tie surface where the new weld nut is to he installed. 4. Install the new weld nut (P/N 11514034) into position. 5. Migweld the new weld nut to the front end lower tie surface in the correct location. 6. Use a new fastener (P/N 11515926). CAUTION: Proper operation of the inflatable restraint Front End Discriminating Sensor requires the sensor be rigidly attached to the vehicle structure and the arrow on the sensor be pointing towards the front of the vehicle. INSTALL OR CONNECT 1. The sensor to the vehicle, make sure the arrow is pointing toward the front of the vehicle. 2. The sensor mounting fasteners. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 1375 TIGHTEN ^ The fasteners to 10 N.m (89 lb in.). 3. The electrical connector and the connector position assurance (CPA). ^ Enable the SIR system. Refer to "Enabling the SIR System." See: Body and Frame/Interior Moulding / Trim/Dash Board / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 1376 Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as "the portion of the vehicle which is crushed, bent, or damaged due to a collision." For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, it must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor Also, if you follow a diagnostic trouble code table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1388 Clutch Switch: Service and Repair REMOVE OR DISCONNECT 1. Wire harness connector from clutch pedal position switch. 2. Clutch pedal position switch from clutch pedal assembly. INSTALL OR CONNECT 1. Clutch pedal position switch to clutch pedal assembly. 2. Wire harness connector to clutch pedal position switch. 3. Verify proper operation of switch. The starter should engage only when clutch is fully disengaged. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1398 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1399 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1400 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1410 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1411 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 1412 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1418 Ignition Switch Lock Cylinder: Service and Repair Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations LH Engine/Transaxle LH Front Of Engine/Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Neutral Safety Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1431 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1432 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1433 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1434 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1435 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1436 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1437 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1438 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1439 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1440 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1441 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1442 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1443 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1444 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1445 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1446 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove Pressure switch assembly, (6 bolts). Important Inspect the O-rings for the pressure switch assembly for any damage. INSTALL OR CONNECT 1. Install the pressure switch assembly making sure all O-rings are in place. 2. Torque the 6 bolts holding the pressure switch assembly to 12 N.m (9 lb. ft.). 3. Install the transaxle case side cover. Refer to "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1474 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1475 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1481 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 1482 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1492 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1493 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1494 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1499 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1500 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1501 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1502 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1503 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1504 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 1509 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1515 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1516 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1517 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1522 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1523 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1524 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1525 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1526 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 1527 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 1532 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 1535 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1536 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1537 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1538 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 1541 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 1542 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 1543 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations LH Center Console LH Center Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 1549 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1550 Power Window Switch: Diagrams Master Window Switch: 4 Door (C1 And C2) Master Window Switch: 4 Door (C1 And C2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1551 Rear Window And Door Lock Switches Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Washer Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper/Washer Switch Wiper Switch: Locations Windshield Wiper/Washer Switch LH I/P And Steering Column LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper/Washer Switch > Page 1560 Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1561 Wiper Switch: Service and Repair Since the Turn Signal Switch and Wiper Switch are part of the Steering Column, refer to STEERING COLUMN UNIT REPAIR for procedures and additional information. You may also need to refer to this area to remove other Steering Column components for access. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1567 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1568 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1569 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1570 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1571 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1572 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1573 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 1576 Alignment: Specifications Alignment Specifications Front Caster ......................................................................................................................................... ............................. +3.30 to +5.30° (+4.30 +/- 1.00°) Front Camber ................................................... ................................................................................................................... -1.20 to +0.80° (-0.20 +/1.00°) Individual Toe ........................................................................................................................... ......................................... -0.07 to +0.17° (+0.05 +/- 0.12°) (Measure Toe Angles With Steering Wheel At Level Position, Visually Aligned With Column.) Sum Toe .............................................................................................................................................. ............................... -0.15 to +0.35° (+0.10 +/- 0.25°) Cross Camber ................................................. ...................................................................................................................... -1.00 to +1.00° (0.00 +/1.00°) (Slight Cross Camber Specification Differences Can Be Made When Servicing Vehicle For Steering Pull.) Cross Caster ........................................................................................................................................ ................................. -1.00 to +1.00° (0.00 +/- 1.00°) Rear Camber ................................................... .................................................................................................................... -1.00 to +0.50° (-0.25 +/0.75°) Rear Sum Toe .......................................................................................................................... .......................................... -0.10 to +0.50° (+0.20 +/- 0.30°) Rear Thrust Angle ................................ ................................................................................................................................ -0.25 to +0.25° (0.00 +/- 0.25°) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 1577 Alignment: Specifications Torque Specifications Strut to Knuckle Nuts ........................................................................................................................... ................................................ 180 Nm (133 ft. lbs.) Tie Rod Jam Nut ............................................... ........................................................................................................................................ 75 Nm (55 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1578 Alignment: Service Precautions NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener tightening specification and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Definition of Terms Alignment: Description and Operation Definition of Terms Camber Camber is the tilting of the front wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is "positive" (+). When the wheels tilt inward at the top, the camber is "negative" (-). The amount of tilt is measured in degrees from the vertical. Camber setting will influence directional control and tire wear. Caster Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Definition of Terms > Page 1581 Caster is the tilting of the front steering axis (at the top) either forward or backward from the vertical. A backward tilt is "positive" (+) and a forward tilt is "negative" (-). Caster influences directional control of the steering but does not affect tire wear. Caster is affected by vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect the caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more "positive" caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less "positive" caster. Toe-In Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Definition of Terms > Page 1582 Toe is a measurement of how much the front of the wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is "positive" (+). When the wheels are turned out, toe is "negative" (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also serves to offset the small deflections of the wheel support system which occurs when the vehicle is rolling forward. In other words, even when the wheels are set to toe in or out slightly when the vehicle is standing still, they tend to roll parallel on the road when the vehicle is moving. Toe affects tire wear. Thrust Angle The front wheels aim or steer the vehicle, but the rear wheels control tracking. This tracking action is relative to thrust angle. Thrust angle is defined as the path that the rear wheels will take. Ideally, the thrust angle is geometrically aligned with the body centerline. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Definition of Terms > Page 1583 Alignment: Description and Operation General Description Wheel alignment refers to the angular relationship between the wheels, control arms, suspension and the ground. When measured, the vehicle should have a full fuel tank, no passengers, and with no other loading or items in the trunk or passengers compartment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1584 Alignment: Testing and Inspection Some degree of torque steer to the right may normally be experienced during heavy throttle application on some front-wheel-drive vehicles that do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and associated difference in axle angle. Vehicles with intermediate shaft assemblies have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1585 start or at lower speeds. A simple measurement to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will then determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause torque steer to be more apparent on a particular vehicle: ^ Large difference in right and left front tire pressure. ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect front tires for difference in brand, construction, or size. If the tires appear similar, change the front tires side to side and re-test the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. ^ Any looseness in control arm bushings, tie rod assemblies or steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead on deceleration. ^ High front trim height which would increase drive axle angle. ^ Binding or tight drive axle joint. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (15 and 30 mph). ^ Incorrect, worn, or loose engine mounts causing adverse drive axle angles. ^ Unequal Engine/Transmission height from the left side to the right side of vehicle. If difference from side to side is more than 6 mm (17/64 inch), change trim heights by installing a stronger spring in the side which is lower, or a weaker spring in the side which is shorter than the specified "Z" heights. Replace only, do not shim engine mounts as this may cause other symptoms. ^ On occasion, side-to-side trim height differences may be the result of a faulty stabilizer shaft. To check this disconnect the stabilizer links, re-measure trim heights. If the side-to-side difference is corrected, replace the stabilizer shaft. If there is no change in trim height do not change the stabilizer shaft. A trim height difference of more than 6 mm (17/64 inch), indicates a possible bent, stabilizer shaft, attaching links, or a bent suspension component that may need replacement. The following conditions affect vehicle handling and/or a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ Incorrect front-wheel alignment or a rear-wheel alignment condition which would cause the vehicle to not track straight. A difference in the front wheel to rear wheel measurement compared side to side may indicate a "dog track" condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or other condition. Front-wheel caster should be equal or within specifications and camber may be biased slightly to offset a lead condition. ^ Suspension support misalignment. ^ Front suspension damage, such as a bent strut. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection Alignment: Service and Repair Preliminary Inspection Steering and ride complaints are not always the result of improper alignment. Another possibility is tire "lead" due to worn or improperly manufactured tires. "Lead" is the vehicle's deviation from a straight path on a level road without pressure on the steering wheel. Refer to "Steering, Suspension, Tire And Wheels Diagnosis," for the procedure to determine if the vehicle has a lead problem. Before making any adjustment affecting wheel alignment, make the following inspections to ensure correct alignment readings and alignment adjustments. Inspect: 1. All tires for proper inflation pressures. Also check that tires have about the same tread wear. 2. Hub and bearing assemblies for excessive wear; correct if necessary. 3. Ball joints and tie rod ends; if they are loose, correct them before adjusting. 4. Run-out of wheels and tires. 5. Vehicle trim height. If out of limits and a correction is to be made, do so before adjusting alignment.. 6. Strut dampeners for proper operation. 7. Control arms for loose bushings. 8. Stabilizer shaft for loose or missing parts. 9. Suspension and steering components for damage and replace parts as necessary. Consideration must be given to excess loads, such as tool boxes, sample cases, etc. If these items are normally carried in the vehicle, they should remain in the vehicle during alignment adjustments. Loads such as these should be centered in the vehicle whenever possible to minimize their effects. Consideration should also be given to the condition of the equipment being used to adjust alignment. Be sure to follow the equipment manufacturer's instructions. Regardless of the equipment used to adjust alignment, the vehicle must be on a level surface, both fore-and-aft and sideways. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1588 Alignment: Service and Repair Ride/Trim Height Measurement and Adjustment Vehicle Ride Height Measurement Locations Prior to measuring vehicle trim height, prepare the vehicle as follows: 1. Check to be sure that: A. The fuel gage reads full. B. The spare tire and tools are properly located. C. The vehicle is free of ice, snow and mud accumulations. 2. Set front and rear tire pressure to within plus or minus 20 kPa (3 psi) of recommended pressure shown on tire placard. If two load conditions are shown on placard, use the lower load condition. 3. Close engine compartment hood and all doors. 4. Up to 7kg (15.5 lbs.) may be left in trunk if it is located approximately on vehicle centerline. Remove items necessary to meet this requirement. 5. Measure the vehicle trim height as follows: ^ "Z" and "J" Dimensions: Lift front bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. Push front bumper down approximately 38.0 mm (1 1/2 inch). Gently repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. True heights are the average of the high and low measurements. ^ "K" Dimension: Lift rear bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "K" dimension. Push rear bumper down approximately 38.0 mm (1 1/2 inch). Gently remove hand and let vehicle rise on its own. Repeat twice for a total of 3 times. Measure "K" dimension. True heights are the average of the high and low measurements. Trim Height Measurements Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1589 Prior to measuring vehicle trim height, prepare the vehicle as follows: 1. Check to be sure that: A. The fuel gage reads full. B. The spare tire and tools are properly located. C. The vehicle is free of ice, snow and mud accumulations. 2. Set front and rear tire pressure to within plus or minus 20 kPa (3 psi) of recommended pressure shown on tire placard. If two load conditions are shown on placard, use the lower load condition. 3. Close engine compartment hood and all doors. 4. Up to 7kg (15.5 lbs.) may be left in trunk if it is located approximately on vehicle centerline. Remove items necessary to meet this requirement. 5. Measure the vehicle trim height as follows: ^ "Z" and "J" Dimensions: Lift front bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. Push front bumper down approximately 38.0 mm (1 1/2 inch). Gently repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. True heights are the average of the high and low measurements. ^ "K" Dimension: Lift rear bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "K" dimension. Push rear bumper down approximately 38.0 mm (1 1/2 inch). Gently remove hand and let vehicle rise on its own. Repeat twice for a total of 3 times. Measure "K" dimension. True heights are the average of the high and low measurements. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1590 Alignment: Service and Repair Front Wheel Alignment Measuring Front Alignment Angles Important: ^ Install alignment equipment following equipment manufacturer's instructions. ^ Jounce front and rear bumpers three times to normalize suspension prior to measuring angles. ^ Measure alignment angles and record the readings. If adjustments are necessary, make them in the following order: 1. Camber. 2. Toe. Front Caster Adjustment Caster is not adjustable. If the caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace parts as necessary. Refer to "Body And Frame" to determine proper underbody alignment. Front Camber Adjustment Important: When camber adjustment is necessary, Refer to "Front Suspension" for instructions on modifying the front strut. GENERAL PROCEDURE ^ Loosen both strut to knuckle nuts just enough to allow movement. ^ Adjust the camber to specification by moving top of wheel in or out. Refer to "Specifications." ^ Tighten the strut-to-knuckle nuts to 180 Nm (133 ft. lbs.). Front Toe Adjustment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1591 DISASSEMBLE 1. Be sure steering wheel is set in a straight ahead position within +/- 5 degrees. 2. Loosen jam nut. 3. Adjust toe to specification by turning adjuster. 4. Tighten jam nut to 75 Nm (55 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 1592 Alignment: Service and Repair Rear Wheel Alignment Rear wheel alignment is not adjustable. If the camber and toe angles are not within the specifications, inspect for underbody or rear suspension damage. Refer to "Body And Frame" to determine proper underbody alignment. After front wheel alignment has been completed the rear alignment angles should be checked if there is excessive rear tire wear or wheels do not track properly. Rear wheels should be parallel to and the same distance from the vehicles centerline. If tires do not track correctly after a front wheel alignment, no amount of adjustment will correct the problem. Poor tracking or excessive rear tire wear after a front wheel alignment usually indicates that the axle housing, frame, or suspension arms have been bent. Refer to "Specifications" for rear alignment angles. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 1598 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1599 Fuel Pressure: Service Precautions CAUTION: The following procedures and conditions MUST be followed or parts and system damage could result. 1. Do not operate the fuel pump without fuel in the lines. 2. Torque all screw couple fittings and fasteners to the specified torque. 3. If a fastener needs to be replaced, use the correct part number fastener or a fastener of equal size and strength (or stronger) for that application. 4. Always use a backup wrench when loosening or tighting a screw couple fitting. 5. On fuel injected models do not depress the accelerator pedal while trying to start the car. 6. Handle all fuel injection related parts with care as they may easily be damaged. 7. Always use new gaskets or O-rings when installing fuel lines or injectors. 8. Lightly lubricate O-rings and flare connections with gasoline. Do NOT use engine oil, gear lubricant or brake fluid. 9. Take care not to nick or scratch any nylon fuel lines. If damaged, they must be replaced. 10. Always cover nylon fuel lines with a wet towel before using a torch near them. Never expose the vehicle to temperatures higher than 115°C (239° F) for more than one hour, or more than 90°C (194°F) for any extended period. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1600 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1601 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1602 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1603 Diagnostic Chart Gauge Hookups CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn the in-tank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION Number(s) below refer to the step number(s) on the Diagnostic Table. 2. To relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition switch is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gage should be 284-325 kPa (41-47 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that can not maintain a constant fuel pressure has a leak in one or more of the following areas: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1604 ^ The fuel pump check valve. ^ The fuel pump flex pipe. ^ The valve or valve seat within the fuel pressure regulator. ^ The fuel injector(s). 4. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector width will increase. NOTE: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. This can cause false indications by the scan tool. 7. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the Engine OFF. 11. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 12. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a faulty fuel pressure regulator. 15. A lean condition may result from the fuel pressure being below 284 kPa (41 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold), hesitation, poor driveability, lack of power, surging, and misfiring. 16. Restricting the fuel return pipe causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gage outlet hose is pinched. 22. Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. 24. The fuel pressure regulator filter screen is designed to trap any contaminants introduced during engine assembly. If the fuel pressure regulator screen is dirty, it can be removed with a small pick and discarded without potential harm to the fuel pressure regulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 1608 Air/Fuel Mixture: Adjustments The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: Customer Interest Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 1617 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: All Technical Service Bulletins Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 1623 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1624 Idle Speed: By Symptom Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1625 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1626 Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1627 For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1628 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1629 Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1630 Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1631 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Specifications Air Cleaner Fresh Air Duct/Hose: Specifications Resonator Upper Attaching Bolt .......................................................................................................... ....................................................... 7 Nm (61 lb. in.) Headlamp Assembly Retaining Screws ....................................................................................................................................................... 7 Nm (61 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct Air Cleaner Fresh Air Duct/Hose: Service and Repair Front Air Duct Removal Procedure 1. Remove the air cleaner outlet splash shield. 2. Remove the LH headlamp assembly retaining screws. 3. Remove the LH headlamp assembly. 4. Disconnect the LH headlamp electrical connector(s). 5. Remove the front air cleaner outlet duct upper push in retainer. 6. Remove the resonator front push in retainer. 7. Raise the vehicle. 8. Remove the LF tire and wheel. 9. Remove the LF wheel house panel. 10. Remove the front air cleaner outlet duct lower retaining screw. 11. Remove the front air cleaner outlet duct through headlamp assembly opening. 12. Remove the resonator rear push in retainer and upper attaching bolt. 13. Remove the resonator assembly through wheel house opening. Installation Procedure 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push in retainer and the upper attaching bolt. Tighten the Resonator upper attaching bolt to 7 Nm (61 lb. in.). 3. Install the front air cleaner outlet duct through the headlamp assembly opening. 4. Install the front air cleaner outlet duct lower retaining screw. 5. Install the LF wheel house panel. 6. Install the LF tire and wheel. 7. Lower the vehicle. 8. Install the resonator front push in retainer. 9. Install the front air cleaner outlet duct upper push in retainer. 10. Install the LH headlamp electrical connector(s). 11. Install the LH headlamp assembly retaining screws. Tighten the headlamp assembly retaining screws to 7 Nm (61 lb. in.). 12. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct > Page 1638 Air Cleaner Fresh Air Duct/Hose: Service and Repair Fresh Air Hose Removal Procedure 1. Remove the air cleaner outlet resonator mounting screws. 2. Disconnect the air cleaner outlet resonator clamp at throttle body. 3. Remove the air cleaner outlet duct from air cleaner outlet resonator and air cleaner assembly. 4. Disconnect the crankcase vent hose from the air cleaner outlet duct. 5. Remove the air cleaner outlet resonator. Installation Procedure Important: Be sure that the air cleaner outlet resonator seals to the throttle body. 1. Install the air cleaner outlet resonator to the throttle body. 2. Connect the crankcase vent hose to the air cleaner outlet duct. 3. Install the air cleaner outlet resonator mounting screws. Tighten: ^ Air cleaner outlet resonator mounting screws to 5-7 Nm 60-84 lb. in.). ^ Air cleaner outlet resonator clamp to 4-5 Nm 35-44 lb in). 4. Install the air cleaner outlet duct to the air cleaner outlet resonator and the air cleaner assembly. Tighten Air cleaner outlet duct clamps to 45 Nm (35-44 lb. in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1647 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1653 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1654 Air Filter Element: Specifications Air Cleaner Cover Screws ................................................................................................................... ........................................................ 3 Nm (26 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1655 Air Filter Element: Service and Repair Air Filter Removal Procedure 1. Remove the upper air cleaner screws. 2. Remove the air cleaner cover. 3. Remove the air cleaner filter from lower air cleaner housing. 4. Inspect the air cleaner filter for dust, dirt, and water. 5. Replace if required. Installation Procedure 1. Install the air cleaner filter into the lower air cleaner housing. 2. Install the air cleaner cover to air cleaner housing. 3. Install the air cleaner screws. Tighten the air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition - Revised Spark Plug Gap Spark Plug: Technical Service Bulletins Ignition - Revised Spark Plug Gap File In Section: 6E - Engine Fuel & Emission Bulletin No.: 77-65-11A Date: May, 1997 INFORMATION Subject: Production Spark Plug Gap Change Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN T - RPO LD9) This bulletin is being revised to add Chevrolet Malibu to models. Please discard Corporate Bulletin Number 77-65-11 (Section 6E - Engine Fuel & Emission). A change in spark plug gap has been made to reduce spark plug fouling during repeated low speed operation of these vehicles at assembly plants, rail heads and dealer/retailer unloading points. The electrode gap of the production spark plugs has been reduced from 1.52 mm (0.060 in) to 1.27 mm (0.050 in). If a spark plug is removed to perform a service procedure and the gap is found to be 1.52 mm (0.060 in) and the spark plugs are functioning normally, do not change the spark plugs. Original equipment spark plugs will have the production part number imprinted on the ceramic insulator. The 1.52 mm (0.060 in) electrode gap spark plug will have a production part number of 25164044 and the 1.27 mm (0.050 in) electrode gap spark plug will have a production part number of 25312636. The service spark plug part number for all 1997 LD9 engines is 25164048 with an electrode gap of 1.27 mm (0.050 in). Important: Do not mix spark plugs with different electrode gaps on the same engine. If it becomes necessary to change a spark plug in any of these vehicles equipped with spark plugs that have a 1.52 mm (0.060 in) gap, replace all four spark plugs with GM Part Number 25164048 with the electrode gap set at 1.27 mm (0.050 in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 1678 Spark Plug: Specifications Spark Plug Torque 13 lb. ft. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1679 Spark Plug: Application and ID Spark Plug Identification Chart Spark Plugs: GM Part # 24161677 A-C Type 41-928 Gapped @ 1.52mm (0.060 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1680 Spark Plug: Description and Operation NOTE: This engine has aluminum cylinder heads. Allow the engine to cool before removing spark plugs, or the spark plug threads in the cylinder head may be damaged. - This engine uses tapered seat resistor type spark plugs without gaskets. Always replace plugs with the same spark plug as listed. DESCRIPTION Normal service is assumed to be a mixture of idling, slow speed, and high speed driving. Occasional or intermittent highway driving is needed for good spark plug performance because it gives increased combustion heat that bums away any excess deposits of carbon or oxides that have built up from frequent idling or continual stop-and-go driving. Spark plugs are protected by an insulating boot made of special heat-resistant material which covers the spark plug terminal and extends downward over a portion of the plug insulator. These boots prevent flash-over which causes engine mis-firing. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of a high-tension field, and has no effect on ignition performance. Usually it can be detected only in darkness. This discharge may repel dust particles, leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Spark plugs must operate within certain temperature limits if they are to provide the performance and service life expected. The spark plug selected for an engine is based on the normal service which the engine was designed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1681 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1682 Spark Plug: Service and Repair CAUTION: To avoid engine damage, do not remove spark plugs when engine is warm. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Electronic ignition module assembly 4 bolts and connector. 3. Remove by pulling straight up on housing. 4. Use tool J 36011 or equivalent to remove connector assembly(s) if stuck to the spark plugs. - Use tool by first twisting then pulling up on the connector assembly. 5. Remove debris from area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. INSTALL OR CONNECT 1. Adjust spark plug gap to 1.52 mm (0.060 inch) using a round wire type spark plug gap gage. While gapping plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start spark plugs into the cylinder head. Tighten Spark plugs to 18 Nm (13 lbs. ft.). 3. Reinstall onto the module assembly any spark plug boot connector assembly that stuck to a spark plug. - Check to be sure spring terminal is inside boot. - Reapply dielectric lubricant to insulator boot. 4. Locate module assembly over spark plugs and push straight down. 5. Clean any loose lubricant that is present on the module assembly to cam housing bolts. 6. Apply threadlocker onto the module assembly to cam housing bolts. CAUTION: Hand start the module assembly to cam housing bolts. Tighten Bolts to 22 Nm (16 lbs. ft.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1683 7. Electrical connector. 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Intake Valve Cold Valve Lash ................................................................................................................................... 0.13 - 0.17 mm (0.005 - 0.007 inches) Exhaust Valve Cold Valve Leash .............................................................................................................................. 0.13 - 0.17 mm (0.005 - 0.007 inches) Intake Valve Hot Valve Leash ................................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Exhaust Valve Hot Valve Leash ............................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair Timing Belt: Service and Repair GM does not specify if this engine is an interference engine or not. To be safe, always observe the following precautions. If cylinder head is installed on the cylinder block: - DO NOT turn the crankshaft or camshaft if the timing belt/chain is not installed or if the camshaft timing has not been confirmed to be correct. - DO NOT rotate engine backwards. - If a broken or "jumped" timing belt/chain is suspected, DO NOT use the starter to crank the engine. - If a "catch" is felt when rotating the engine by hand, DO NOT attempt force the engine to rotate past the "catch". If cylinder head is removed (overhead cam engines): - Do not set cylinder head on a flat surface with combustion chamber down. When re-installing a cylinder head: - Confirm that the crankshaft AND camshaft gears align with their respective timing marks or confirm that all shafts are set to TDC for cylinder # 1 BEFORE placing the cylinder head onto the cylinder block. If the timing chain/belt has broken of "jumped time" with the engine running, always check for bent valves by pressurizing each cylinder with air with it's valves in the closed position. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1697 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1698 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1699 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement Drive Belt: Service and Repair Accessory Drive Belt Replacement Drive Belt Replacement Tools Required J 37059 Accessory Drive Belt Tensioner Wrench. Caution: To avoid personal injury when rotating the accessory drive belt tensioner, use a tight fitting 13 mm wrench that is at least 46 cm (18 in) long. Use J 37059 in order to remove the accessory drive belt by rotating the tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 1702 Drive Belt: Service and Repair Pump Drive Belt SERPENTINE BELT These vehicles have the power steering pump driven by a serpentine belt. The serpentine belt is self adjusting within tensioner operating limits. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Specifications Air Cleaner Fresh Air Duct/Hose: Specifications Resonator Upper Attaching Bolt .......................................................................................................... ....................................................... 7 Nm (61 lb. in.) Headlamp Assembly Retaining Screws ....................................................................................................................................................... 7 Nm (61 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct Air Cleaner Fresh Air Duct/Hose: Service and Repair Front Air Duct Removal Procedure 1. Remove the air cleaner outlet splash shield. 2. Remove the LH headlamp assembly retaining screws. 3. Remove the LH headlamp assembly. 4. Disconnect the LH headlamp electrical connector(s). 5. Remove the front air cleaner outlet duct upper push in retainer. 6. Remove the resonator front push in retainer. 7. Raise the vehicle. 8. Remove the LF tire and wheel. 9. Remove the LF wheel house panel. 10. Remove the front air cleaner outlet duct lower retaining screw. 11. Remove the front air cleaner outlet duct through headlamp assembly opening. 12. Remove the resonator rear push in retainer and upper attaching bolt. 13. Remove the resonator assembly through wheel house opening. Installation Procedure 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push in retainer and the upper attaching bolt. Tighten the Resonator upper attaching bolt to 7 Nm (61 lb. in.). 3. Install the front air cleaner outlet duct through the headlamp assembly opening. 4. Install the front air cleaner outlet duct lower retaining screw. 5. Install the LF wheel house panel. 6. Install the LF tire and wheel. 7. Lower the vehicle. 8. Install the resonator front push in retainer. 9. Install the front air cleaner outlet duct upper push in retainer. 10. Install the LH headlamp electrical connector(s). 11. Install the LH headlamp assembly retaining screws. Tighten the headlamp assembly retaining screws to 7 Nm (61 lb. in.). 12. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct > Page 1710 Air Cleaner Fresh Air Duct/Hose: Service and Repair Fresh Air Hose Removal Procedure 1. Remove the air cleaner outlet resonator mounting screws. 2. Disconnect the air cleaner outlet resonator clamp at throttle body. 3. Remove the air cleaner outlet duct from air cleaner outlet resonator and air cleaner assembly. 4. Disconnect the crankcase vent hose from the air cleaner outlet duct. 5. Remove the air cleaner outlet resonator. Installation Procedure Important: Be sure that the air cleaner outlet resonator seals to the throttle body. 1. Install the air cleaner outlet resonator to the throttle body. 2. Connect the crankcase vent hose to the air cleaner outlet duct. 3. Install the air cleaner outlet resonator mounting screws. Tighten: ^ Air cleaner outlet resonator mounting screws to 5-7 Nm 60-84 lb. in.). ^ Air cleaner outlet resonator clamp to 4-5 Nm 35-44 lb in). 4. Install the air cleaner outlet duct to the air cleaner outlet resonator and the air cleaner assembly. Tighten Air cleaner outlet duct clamps to 45 Nm (35-44 lb. in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 1719 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1725 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1726 Air Filter Element: Specifications Air Cleaner Cover Screws ................................................................................................................... ........................................................ 3 Nm (26 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1727 Air Filter Element: Service and Repair Air Filter Removal Procedure 1. Remove the upper air cleaner screws. 2. Remove the air cleaner cover. 3. Remove the air cleaner filter from lower air cleaner housing. 4. Inspect the air cleaner filter for dust, dirt, and water. 5. Replace if required. Installation Procedure 1. Install the air cleaner filter into the lower air cleaner housing. 2. Install the air cleaner cover to air cleaner housing. 3. Install the air cleaner screws. Tighten the air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Fluid Filter - A/T: Service and Repair 3T40 3T40 REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Place drain pan under transaxle oil pan. 3. Oil pan bolts from the front and sides only. 4. Loosen rear oil pan bolts approximately 4 turns. NOTICE: Do not damage the transaxle case or oil pan sealing surfaces. 5. Lightly tap oil pan with rubber mallet or pry to allow oil to drain. Inspect - Inspect oil color. - Refer to "Checking Oil Color, Level and Condition." 6. Remaining oil pan bolts, oil pan and gasket. 7. Oil filter and O-ring. Inspect - O-ring may be stuck in the case. Clean - Transaxle case and oil pan gasket surfaces with solvent and air dry. All traces of old gasket material must be removed. INSTALL OR CONNECT 1. Coat seal with a small amount of TRANSJEL J 36850 or equivalent. 2. New seal into case. 3. New filter into case. 4. Oil pan and new gasket. 5. Oil pan bolts, refer to "Fastener Tightening Specifications. " Inspect - Refer to "Valve Body Cover and Oil Pan Bolts" for inspection of bolts and washers. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 > Page 1732 - Use adhesive/sealant compound GM P/N 12345382 or equivalent to reduce the potential for oil leaks on indicated bolt, refer to the image. 6. Lower vehicle. 7. Fill transaxle to proper level with DEXRON III oil. Adjust - "Cold" oil level reading for initial fill. Do not overfill. 8. Follow the "Transaxle Oil Level Checking Procedure." Inspect - Check oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 > Page 1733 Fluid Filter - A/T: Service and Repair 4T40-E Oil Filter and Seal REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Drain oil, refer-to "Changing Oil and Filter." 3. Oil pan attaching bolts, oil pan and gasket, refer to "Transaxle Oil pan and Gasket." 4. Oil filter assembly. 5. Filter neck seal from transaxle case using a small screwdriver and being careful not to score case during removal. The filter seal is not reusable and should be discarded. INSTALL OR CONNECT 1. New oil filter and new oil filter seal. Tap gently and evenly on the seal to prevent damage to the case bore or seal. 2. Oil pan gasket; may be reused, unless sealing ribs are damaged. If damaged, use new gasket. 3. Oil pan and attaching bolts, refer to "Transaxle Oil pan and Gasket." Tighten Pan bolts to 12 N.m (9 lb. ft.). 4. Lower vehicle. 5. Fill transaxle to proper level with DEXRON III Inspect - Oil pan gasket for leaks. Changing Oil and Filter Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 > Page 1734 4T40E REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Place drain pan under transaxle oil pan. 3. Oil pan bolts from the front and sides only. 4. Loosen rear oil pan bolts approximately 4 turns. NOTICE: Do not damage the transaxle case or oil pan sealing surfaces. 5. Lightly tap oil pan with rubber mallet or pry to allow oil to drain. Inspect - Inspect oil color. - Refer to "Checking Oil Color, Level and Condition." 6. Remaining oil pan bolts, oil pan and gasket. 7. Oil filter and O-ring. Inspect - O-ring may be stuck in the case. Clean - Transaxle case and oil pan gasket surfaces with solvent and air dry. All traces of old gasket material must be removed. INSTALL OR CONNECT 1. Coat seal with a small amount of TRANSJEL J 36850 or equivalent. 2. New seal into case. 3. New filter into case. 4. Oil pan and new gasket. 5. Oil pan bolts, refer to "Fastener Tightening Specifications. " Inspect - Refer to "Valve Body Cover and Oil Pan Bolts" for inspection of bolts and washers. - Use adhesive/sealant compound GM P/N12345382 or equivalent to reduce the potential for oil leaks on indicated bolt, refer to the image. 6. Lower vehicle. 7. Fill transaxle to proper level with DEXRON III oil. Adjust - "Cold" oil level reading for initial fill. Do not overfill. 8. Follow the "Transaxle Oil Level Checking Procedure." Inspect - Check oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation DESCRIPTION A woven plastic strainer is located on the lower end of the fuel sender. OPERATION This filter prevents dirt from entering the fuel line and also stops water unless the filter becomes completely submerged in water. This filter is self cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Therefore, should this occur, the fuel tank should be removed and thoroughly cleaned and the tank filter replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 1742 Fuel Pump Pickup Filter: Service and Repair Removal Procedure 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release 2. Drain fuel tank. Refer to Draining Fuel Tank. 3. Remove the fuel tank. Refer to Fuel Tank. 4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly. 5. Note strainer position for future reference. 6. Support the reservoir with one hand and grasp the strainer with the other hand. 7. Using a screwdriver to pry the strainer ferrule off the reservoir. 8. Discard the strainer. Installation Procedure 1. Install the new strainer (1) to reservoir. 2. Support the reservoir with one hand and grasp the strainer with the other hand twisting the strainer into position. 3. Install the fuel sender assembly. Refer to Fuel Sender Assembly. 4. Install the fuel tank. Refer to Fuel Tank. 5. Refill tank. 6. Inspect for fuel leaks: 6.1. Turn the ignition switch to the ON position for two seconds. 6.2. Turn the ignition switch OFF position for ten seconds. 6.3. Turn the ignition switch to the ON position. 6.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Specifications Heater Hose: Specifications Heater Outlet Pipe Nut ........................................................................................................................ ...................................................... 25 N.m (18 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses Heater Hose Routing - 2.4L Check all heater hose routing for installation to avoid contact with any obstruction that could result in a damaged hose. Some hoses are equipped with conduit in areas where rubbing may occur. Always reinstall conduit or heat sleeves in the same location when replacing a hose. Tool Required: J 42202 Quick Connect Remover Remove or Disconnect 1. Drain engine coolant. 2. Heater hose from heater pipe by squeezing tabs on quick-connect. ^ J 42202 can be used to separate quick-connect and retainer from pipe. 3. Heater hose from inlet housing. 4. Raise vehicle. 5. Heater hoses from heater core. Install or Connect 1. Heater hoses to heater core. 2. Lower vehicle. 3. Top heater core hose to inlet housing. 4. Heater hose to heater pipe quick-connect, pull to verify connection. 5. Refill engine coolant. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 1753 Heater Hose: Service and Repair Heater Outlet Pipe ^ Part of the coolant pump outlet assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 1754 Heater Hose: Service and Repair Quick Connect Retainer The quick connect retainer can be removed from the heater pipe and replaced if necessary. it is recommended that the retainer be replaced whenever the quick-connect is disconnected. If the retainer is to be reused, the use of J 42202 is recommended. Tool Required: J 42202 Quick Connect Remover 1. Clamp J 42202 around the heater pipe. 2. Slide J 42202 under the quick connect retainer 3. Apply pressure towards the quick connect retainer until the ramps release from the pipe. 4. Remove the quick connect retainer from the pipe. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: Customer Interest A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 1763 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: All Technical Service Bulletins A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 1769 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: All Technical Service Bulletins PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 1775 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 1776 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 1782 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 1783 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1784 Hose/Line HVAC: Specifications A/C Compressor and Condenser Hose Bolt .............................................................................................................................................. 33 N.m (24 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1785 Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1786 Hose/Line HVAC: Service and Repair Compressor/Condenser Hose Assembly - 2.2L Compressor/Condenser Hose Assembly - 2.4L Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Switch connection on discharge line. 3. Cruise control module (if equipped). 4. Suction line (accumulator to compressor) at accumulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1787 5. Upper closeout panel. 6. Connection at the condenser. 7. Raise vehicle. 8. Block fitting at the rear head of the compressor. 9. Compressor/condenser hose assembly. Important ^ Remove and discard all used O-ring seals and "Sealing Washers". Install or Connect 1. Compressor/condenser hose assembly. 2. Block fitting to rear head of compressor using new "Sealing Washers". 3. Lower vehicle. 4. Suction line at the accumulator using a new O-ring seal. 5. Connection at the condenser using new O-ring seals. 6. Switch connection on discharge line. 7. Cruise control module. 8. Upper closeout panel. 9. Evacuate and charge A/C system. 10. Check system operation and leak test. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement Power Steering Line/Hose: Service and Repair Gear Inlet Hose Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 1792 REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear inlet hose from pump. 4. Raise vehicle. 5. Gear inlet hose from steering gear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 1793 INSTALL OR CONNECT 1. Route new gear inlet hose to steering gear. 2. Gear inlet hose to steering gear. 3. Lower vehicle. 4. Install gear inlet hose to pump. ^ Tighten gear inlet hose assembly to 27 Nm (20 ft. lbs.). 5. Fill and bleed power steering system. ^ Bleed air from system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 1794 Power Steering Line/Hose: Service and Repair Gear Outlet Hose Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 1795 REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear outlet hose from pump after sliding spring clamp back. 4. Line retainer (if applicable). 5. Gear inlet hose assembly from rack and pinion steering gear. 6. Gear outlet hose assembly from rack and pinion steering gear. 7. Gear outlet pipe and/or hose from vehicle. INSTALL OR CONNECT 1. Gear outlet hose assembly into position on vehicle. 2. Gear outlet hose assembly to rack and pinion steering gear. Tighten outlet hose assembly to 27 Nm (20 ft. lbs.). 3. Gear inlet hose assembly to rack and pinion steering gear. Tighten hose assembly to 27 Nm (20 ft. lbs.). 4. Line retainer (if applicable). 5. Gear outlet hose to pump and hose clamp. Important: Fill and Bleed air from system. 6. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Specifications Radiator Hose: Specifications Radiator Outlet Hose To Water Pump Cover ..................................................................................................................................... 14 Nm (124 inch lbs.) Radiator Outlet Hose To Engine Oil Pan .................................................................................................................................................. 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Specifications > Page 1799 Radiator Hose: Testing and Inspection Inspect the condition of all hoses and clamps. Hoses should be flexible and show no signs of bulging. Inspect hoses for cracks, cuts, kinks and areas of possible leaks. Check the alignment of the hoses using the reference marks for proper orientation of hoses. Inspect the brackets, supports, ties and clamps. Replace or adjust as needed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Specifications > Page 1800 Radiator Hose: Service and Repair REMOVAL PROCEDURE 1. Negative battery cable. 2. Drain and recover the radiator so the level of the coolant is below the hose being removed. 3. Radiator inlet hose from the radiator and engine coolant outlet. 4. Radiator outlet hose from the radiator and radiator outlet pipe and surge tank. CAUTION: Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break. INSTALLATION PROCEDURE 1. Radiator outlet hose to the radiator and radiator outlet pipe and surge tank. 2. Radiator inlet hose to the radiator and engine coolant outlet. 3. Refill radiator. 4. Negative battery cable. 5. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 1806 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1807 Brake Fluid: Specifications Brake System DOT 3 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Customer Interest: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Coolant: Customer Interest Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Customer Interest: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 1816 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Customer Interest: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 1817 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 05-06-02-002B > Jan > 08 > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: All Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information Coolant: All Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information > Page 1827 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information > Page 1828 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information > Page 1829 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Coolant: All Technical Service Bulletins Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 1834 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 1835 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 05-06-02-002B > Jan > 08 > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: All Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information Coolant: All Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information > Page 1845 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information > Page 1846 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System - Coolant Recycling Information > Page 1847 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Mixture .......................................................................................................................................................... 50/50 of water and ethylene glycol antifreeze Capacity ............................................................................................................................................... .................................................. 10.0 liters (10.5 qt) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1850 Coolant: Fluid Type Specifications ENGINE COOLANT A 50/50 mixture of clean water (preferably distilled) and use only GM Goodwrench(R) DEX-COOL(R) or Havoline(R) DEX-COOL(R) (orange-colored, silicate-free) coolant, or an approved recycled coolant conforming to GM Specification 6038-M (GM P/N 1052103). CAUTION: If silicate coolant is added to the cooling system, premature engine, heater core or radiator corrosion may result. In addition, the coolant will require change SOONER, at 50 000 km (30,000 miles) or 24 months. NOTE: With a complete flush and refill it is recommended to add Engine Coolant Supplement Sealer, (GM P/N 3634621 or equivalent). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1851 Coolant: Service Precautions CAUTION: When adding coolant it is important that you use GM Goodwrench DEX-COOL coolant. If coolant other than DEX-COOL is added to the system, the engine coolant will require change sooner - at 50,000 km (30,000 miles) or 24 months. Do not add cold water to the cooling system with the engine at or above operating temperature. Adding cold water causes rapid cooling, resulting in possible engine damage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1852 Coolant: Description and Operation NOTE: This vehicle was manufactured with GM Goodwrench DEX-COOL. DEX-COOL was developed to last for 240,000 km (150,000 miles) or 5 years whichever occurs first. Make sure only GM Goodwrench DEX-COOL is used when coolant is added or changed. A 50/50 mixture of ethylene glycol (DEX-COOL) and water will provide the following: ^ Freezing protection down to -37°C (-34°F). ^ Boiling protection up to 129°C (265°F). ^ Help keep the proper engine temperature. ^ Rust and corrosion protection. ^ Allow the sensors and switches to operate as designed. CAUTION: Do not use a solution stronger than 70 percent antifreeze. Pure antifreeze will freeze at -22°C (-8°F). DESCRIPTION Some coolant manufacturers are mixing other types of glycol in their coolant formulations; propylene glycol is the most common new ingredient However, propylene glycol is not recommended for use in GM vehicles that were manufactured with GM Goodwrench DEX-COOL. A hydrometer will not always provide a correct measurement of freeze protection when anything other than ethylene glycol and water is being tested. The degree of inaccuracy will vary depending on the proportion of other glycols present in the coolant. Hydrometers test the amount of glycol in a mixture by measuring the specific gravity of the mixture; the more ethylene glycol, the higher the float balls go, and the better the freeze protection. Because ethylene glycol and propylene glycol do not have the same specific gravities, hydrometer readings of mixtures containing propylene glycol give incorrect values. It is recommended that a "refractometer" be used when testing coolant. Refractometers test for the amount of glycol in a coolant mixture by measuring the speed of light as it passes through the fluid and are not affected by the specific gravity of the glycol. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Checking Coolant Level Coolant: Testing and Inspection Checking Coolant Level Check the coolant level in the radiator surge tank every time the hood is up. The level should be near appropriate mark when the system is cold. At normal operating temperature the coolant level should increase. Coolant should be added only to the reservoir or surge tank to raise level to the appropriate mark. If the pressure in the cooling system is too low, or if the coolant does not contain enough ethylene glycol antifreeze, the coolant will boil without the "Temp" indicator light coming on. Pure water could boil at 119°C (247°F) and the "Temp" indicator light would not come on, even with a 103 kPa (15 psi) cooling system. Pure water lacks the necessary rust inhibitors and coolant pump lubricant. The engine should never be run without the pressure cap, or with the cap loose, as the coolant will boil before the "Temp" indicator light comes on. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Checking Coolant Level > Page 1855 Coolant: Testing and Inspection Coolant Concentration Testing NOTE: Coolant testers with centigrade scale or fahrenheit scale can be used to check the antifreeze protection of the coolant. Make sure the refractometer markings are correct. Unless centigrade scale or fahrenheit scale has a provision for temperature correction, test the temperature at which testers are calibrated. If the coolant is warmer or cooler the reading may be incorrect. Follow the manufacturer's directions on tester being used. 1. Release the tip of the pump from the coolant tester housing. 2. Insert the tip of the pump into the surge tank. Make sure the tip of the pump is below the level of the coolant. 3. Press and release the bulb to get a sample. 4. Insert the tip of the pump into the cover plate opening. 5. Press the bulb and allow a few drops to fall onto the measuring surface. Do not open the plastic cover when taking readings because water evaporation can change the readings. 6. Point the coolant tester toward any light and look into the eyepiece. ^ Coolant protection reading is at the point where the dividing line between light and dark crosses the scale (anti-freeze protection is the scale on the right). ^ Temperature scale is reversed from a standard thermometer scale. ^ Below zero readings are on the upper half of the scale. ^ If the readings are not clear, the measuring surface was not cleaned and dried properly. Wipe dry and make a new test. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Service and Repair > Flushing Cooling System Coolant: Service and Repair Flushing Cooling System FLUSHING COOLING SYSTEM Various methods and equipment may be used to flush the system. If using special equipment such as a back flusher, follow the manufacturer's instructions. However, the thermostat should be removed before flushing the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Service and Repair > Flushing Cooling System > Page 1858 Coolant: Service and Repair Filling Cooling System FILLING NOTICE: When adding coolant. it is important that you use GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant mceting GM Specification 6277M. If silicated coolant is added to the system, premature engine. heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner - at 50,OOO km (30.000 miles) or 24 months. 1. Close the radiator drain valve and remove drain tuhe. 2. Install all engine block drain plugs if previously removed. ^ Use pipe sealer when insLalling drain plugs. 3. When adring coolant, it is important that you use GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant meeling GM Specification 6277M. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner - at 50,000 km (30,000 miles) or 24 months. ^ On vehicles produced with the 2.2L engine loosen the engine coolant alr bleed screw located on the top side of the engine coolant outlet. Add coolant until all sir is evacuated through air bleed, Tighten air bleed screw. Important: The bleeder screw must be tightened prior to starting the engine of the vehicle. Failure to tighten the bleeder screw may introduce air into the cooling system, resulting an incomplete coolant fill and possible engine overheating causing component failure. ^ When refilling the engine cooling system. add (2) crushed engine cooling system supplement sealer pellets GM part #3634621 or equivalent. 4. Fill the surge tank [0 the base of the filler neck. 5. Pressure cap onto the surge tank. ^ Block the drive wheels and firrnly apply the parking brake. Shift an automatic transaxle to "Park", or shift manual transaxle to Neutral. Run the engine until the upper radiater hose is hot. ^ Stop the engine. Observe the level of coolant in the surge tank or radiator. If not ahove the "Full" line, allow the engine to cool enough to relieve pressure, then carefully remove surge tank cap and add coolant. 6. Surge tank cap. ^ After servicing the cooling system, an occasional intermittent low coolant light (if equipped) may be encountered during some extreme driving maneuvers. This complaint should he eliminated by removing the surge tank cap and adding coolant to a level just at or above the "Cold Full" mark when the system is cold. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1863 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1864 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1865 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1866 Fluid - A/T: Technical Service Bulletins A/T - Fluid Level Checking And Fill Procedure Revised File In Section: 7 - Transmission Bulletin No.: 63-71-06 Date: March, 1997 SERVICE MANUAL UPDATE Subject: Section 7A - Revised 4T40E Fluid Level Checking and Fill Procedure Models: 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Cutlass 1997 Pontiac Sunfire This bulletin is being issued to revise the 4T40E fluid level checking and fill procedure in Section 7A of the Service Manual. The following procedure should be used for the above listed vehicles. 4T40E Fluid Level Checking and Fill Procedure The fluid level screw is intended to be used for diagnosing a transaxle fluid leak or resetting the transaxle fluid level after service that involves a loss of fluid. Inspect The fluid level should be checked when the transaxle is near 40° C (104° F). A vehicle at room temperature can be brought to 40° C (104° F) by performing the following procedure. Caution: Removal of the fluid level screw when transaxle fluid is hot may cause injury. Use care to avoid contact with the fluid and to avoid transaxle fluid splashing on to the exhaust pipe. The engine must be running when the transaxle fluid level screw is removed, or excessive fluid loss will occur. Transaxle fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fluid level screw. Have a container ready to capture any lost fluid. DO NOT TURN THE ENGINE OFF WITH THE FLUID LEVEL SCREW REMOVED AS YOU CAN BE INJURED BY HOT TRANSAXLE FLUID BEING EXPELLED OUT OF THE FLUID CHECK HOLE. 1. Let vehicle idle for three to five minutes with accessories off. 2. Apply brake. 3. Move shift lever through all gear ranges, pausing three seconds in each range. 4. Place shift lever in Park. Important: Vehicle must be kept level on the hoist. 5. Raise vehicle on hoist. Refer to "General Information". 6. Place oil container under fluid level screw. 7. Remove the fluid level screw with engine running at idle. 8. Fluid level should be at the bottom of fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to Adding Transaxle Fluid. 9. Install fluid level screw. Tighten Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1867 Tighten 12 N.m (106 lb in.). 10. Lower vehicle. 11. Shut off engine. Adding Transaxle Fluid With the engine running, add fluid (DEXRON(R)-III) at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole. 1. Install fluid level screw. Tighten Tighten 12 N.m (106 lb in.). 2. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC 3T40 Bottom Pan Removal ........................................................................................... ...................................................................................... 3.8 liters (4.0 qts) Complete Overhaul .......... .............................................................................................................................................................. ............ 6.6 liters (7.0 qts) Dry ............................................................................................................. ................................................................................................ 8.5 liters (9.0 qts) AUTOMATIC 4T40-E Bottom Pan Removal ........................................................................................ ......................................................................................... 6.5 liters (6.9 qts) Complete Overhaul ....... .............................................................................................................................................................. ............... 9.0 liters (9.5 qts) Dry .......................................................................................................... ............................................................................................... 12.2 liters (12.9 qts) Measurements are approximate. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1870 Fluid - A/T: Fluid Type Specifications DEXRON-III Automatic Transmission Fluid (or equivalent). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information Fluid - A/T: Testing and Inspection Transaxle Oil Information Checking Oil Level Oil Fill And Vent Cap - 4T40E Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 1873 Checking oil level, color and condition at regular intervals will provide early diagnosis information about the transaxle. This information may then be used to correct a condition that, if not detected early, could result in major transaxle repairs. When adding or changing oil, use only DEXRON III. Important When new, automatic transmission oil is red in color. The red dye is to distinguish it from engine oil or anti-freeze. The red dye is not an indicator of oil quality and is not permanent. As the vehicle is driven the transmission oil will begin to look darker in color. The color may eventually appear light brown. A dark brown color with a burnt odor may indicate oil deterioration and signal a need for a transaxle oil change. NOTICE: Do not overfill. Overfilling will cause foaming, loss of oil and possible~damage to the transaxle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 1874 Fluid - A/T: Testing and Inspection Transaxle Oil Level Checking Procedure Checking Oil Level Oil Fill And Vent Cap - 4T40E Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 1875 This procedure has been updated by TSB # 63-71-06 dated March 1997. Start engine and drive vehicle until the transaxle reaches operating temperature of 82-130°C (180-200°F). This temperature is reached after about 24 km (15 miles) of driving. NOTICE: Temperature will greatly affect transmission oil level. If the vehicle is not at normal operating temperature and the proper checking procedures are not followed, the result could be a false reading of the oil level indicator and an incorrect adjustment of the oil level. Inaccurate oil level readings will result if the oil is checked immediately after the vehicle has been operated under certain conditions: In high ambient temperature above 32°C (90°F). - At sustained high speeds. - In heavy city traffic during hot weather. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 1876 - As a towing vehicle. - In commercial service (taxi or police use). If the vehicle has been operated under these conditions, shut the engine off and allow the vehicle to cool for thirty minutes. Then restart the vehicle and continue from step two. The fluid level screw is intended to be used for diagnosing a transaxle fluid leak or resetting the transaxle fluid level after service that involves a loss of fluid. Inspect The fluid level should be checked when the transaxle is near Room temperature or at 40°C (104°F). CAUTION: Removal of the fluid level screw when the transaxle fluid is hot may cause injury. Use care to avoid contact of transaxle fluid to exhaust pipe. The engine must be running when the transaxle fluid level screw is removed, or excessive fluid loss will occur. Since the actual fluid level is unknown, stand clear when removing the fluid level screw. Have a container ready to capture any lost fluid. WARNING: Do not turn the engine off with the fluid level screw removed as you can be injured by hot transaxle fluid being expelled out of the fluid check hole. 1. Let vehicle idle for three to five minutes with accessories off. 2. Apply brake 3. Move shift lever through all gear ranges, pausing three seconds in each range. 4. Place shift lever in Park. Important: Vehicle must be kept level on the hoist. 5. Raise vehicle on hoist. 6. Place oil container under fluid level screw. 7. Remove the fluid with the engine running at idle. 8. Fluid level should be at the bottom of the fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to ADDING TRANSAXLE FLUID. 9. Install fluid level screw. Tighten 12 N.m (106 lb in) 10. Lower vehicle. 11. Shut off engine. Adding Transaxle Fluid: With the engine running, add fluid at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole. 1. Install fluid level screw. Tighten 12 N.m (106 lb in) 2. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Fluid - A/T: Service and Repair 3T40 Automatic Transaxle Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under transmission oil pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. NOTICE: Pry the oil pan down carfully in order to prevent damage to the transmission case or the oil pan sealing surfaces. 5. Lightly tap the oil pan with rubber mallet or pry in order to allow oil to drain. 6. Inspect oil color. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1879 9. Remove the oil pan gasket. 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. Installation Procedure Tools Required J 36850 Transjel Transmission Assembly Lubricant Notice: Use J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Lubricants other than the recommended assembly lube changes the transmission fluid characteristics and causes undesirable shift conditions or filter clogging. 1. Coat seal with a small amount of J 36850, or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1880 5. Install the oil pan. 6. Install the oil pan bolts. Tighten Tighten the bolts to 10 Nm (89 lb in). 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill transmission to proper level with DEXRON III oil 11. Adjust cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1881 Fluid - A/T: Service and Repair 4T40-E Automatic Transaxle 4T40E REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Place drain pan under transaxle oil pan. 3. Oil pan bolts from the front and sides only. 4. Loosen rear oil pan bolts approximately 4 turns. NOTICE: Do not damage the transaxle case or oil pan sealing surfaces. 5. Lightly tap oil pan with rubber mallet or pry to allow oil to drain. Inspect - Inspect oil color. - Refer to "Checking Oil Color, Level and Condition." 6. Remaining oil pan bolts, oil pan and gasket. 7. Oil filter and O-ring. Inspect - O-ring may be stuck in the case. Clean - Transaxle case and oil pan gasket surfaces with solvent and air dry. All traces of old gasket material must be removed. INSTALL OR CONNECT 1. Coat seal with a small amount of TRANSJEL J 36850 or equivalent. 2. New seal into case. 3. New filter into case. 4. Oil pan and new gasket. 5. Oil pan bolts. Tighten Tighten the bottom pan bolts to 12 Nm (106 lb in). Inspect - Refer to "Valve Body Cover and Oil Pan Bolts" for inspection of bolts and washers. - Use adhesive/sealant compound GM P/N12345382 or equivalent to reduce the potential for oil leaks on indicated bolt, refer to the image. 6. Lower vehicle. 7. Fill transaxle to proper level with DEXRON III oil. Adjust - "Cold" oil level reading for initial fill. Do not overfill. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 1882 8. Follow the "Transaxle Oil Level Checking Procedure." Inspect - Check oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Lube Capacity ...................................................................................................................................... ..................................................... 1.9 liters (2.01 qt.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1887 Fluid - M/T: Fluid Type Specifications Manual Transaxle .............................................................................................................................................................. Synchromesh Transmission Fluid Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1892 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1893 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity Without Filter Change ....................................................................................................................................................... 3 3/4 Liters (4 qts.) When Changing the Oil Filter, Up to an Additional 0.946 Liter or One Quart of Oil May Be Needed. Filter Type or Equivalent Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1896 Engine Oil: Fluid Type Specifications Below 60°F (16°C) ............................................................................................................................... ............................................................. SAE 5W-30 Above 0°F (-18°C) ............................................. ........................................................................................................................... SAE 10W-30 (Preferred) Engine oil with the American Petroleum Institute Certified For Gasoline Engine "Starburst" symbol of the proper viscosity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1897 Engine Oil: Description and Operation APPLICATION Oil is applied under pressure to the crankshaft, connecting rods, balance shaft assembly, camshaft bearing surfaces, valve lifters and timing chain hydraulic tensioner. All other moving parts are lubricated by gravity flow or splash. FLOW PROCESS Oil enters the gerotor type oil pump (7) thorough a fixed inlet screen. The oil pump is driven by one of the balance shafts. The oil pump body and the cover are cast aluminum, and the gerotor gears are steel. The pressurized oil from the pump passes through the oil filter (9). The oil filter is located on the left (front) side of the engine block. A by-pass valve (8) in the engine block allows continuous oil flow in case the oil filter should become restricted. Oil then enters the gallery where it is distributed to the balance shafts, the crankshaft (6), the timing chain hydraulic tensioner (10), the lifters (4) and the camshafts (1). FLOW PASSAGES The connecting rod bearings are oiled by constant oil flow passages through the crankshaft connecting the main journals to the rod journals. A groove around each main bearing furnishes oil to the drilled crankshaft passages. An oil cooling hole, which indexes once each revolution with the connecting rod oil feed hole, is drilled in the connecting bearing surface. The pressurized oil passages through the oil flow check valve (11) into the cylinder head (5) and then into each camshaft housing (2). Cast passages feed each valve lifter (4) and drilled passages feed each camshaft baring surface. An engine oil pressure switch or sensor (3) is installed at the end of the intake camshaft housing oil gallery. Oil returns to the oil pan through passages cast into the camshaft housings and the cylinder head. The timing chain housing drains directly into the oil pan. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss Engine Oil: Testing and Inspection Excessive Oil Loss An engine that has excessive oil consumption uses 1.9L (2 qts) of oil, or more, within 2,000 miles (3200 km). The following conditions are indications of excessive on consumption: a. Improperly read oil level indicator (dipstick) ^ Check the oil while the car is standing on a level surface. ^ Allow adequate drain-down time. b. Improper oil viscosity ^ Use the recommended-SAE viscosity for prevailing temperatures. c. Continuous high-speed driving d. Severe hauling, such as a trailer, causing decreased oil mileage. e. Malfunctioning crankcase ventilation system f. External oil leaks ^ Tighten the bolts, as necessary. ^ Replace the gaskets and seals, as necessary. g. Worn or omitted valve guides and/or valve stem seals ^ Replace the valve stem seals. ^ If the valve guides are wore, replace the cylinder head. h. Broken, improperly installed worn or unseated piston rings. i. Piston improperly installed or improperly fitted. j. Plugged cylinder head gasket oil drain holes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss > Page 1900 Engine Oil: Testing and Inspection Low or No Oil Pressure ^ Low oil level. Fill to full mark on oil level indicator. ^ Incorrect or malfunctioning oil pressure switch. ^ Incorrect or malfunctioning oil pressure gauge. ^ Improper oil viscosity for the expected temperature. ^ Oil pump worn or dirty. ^ Malfunctioning oil pump pressure regulator valve. ^ Plugged oil filter. ^ Oil pump screen loose plugged, or damaged. ^ Excessive bearing clearance. Replace as necessary. ^ Cracked, porous or restricted oil galleries. Repair or replace block. ^ Oil gallery plugs missing or incorrectly installed. Install plugs or repair as necessary. ^ Oil diluted by moisture or unburned fuel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss > Page 1901 Engine Oil: Testing and Inspection Oil Consumption Diagnosis ^ Excessive oil consumption (not due to leaks) is the use of 1.9L (2 qts) or more of engine oil within 2,O00 miles (3200 kilometers). The causes of excessive oil consumption include the following conditions: ^ External oil leaks. Tighten bolts and/or replace gaskets and oil seals as necessary. ^ Incorrect oil level or improper reading of oil level indicator. With the vehicle on a level surface, allow adequate drain down time and check for the correct oil level. ^ Improper oil viscosity. Use recommended SAE viscosity for the prevailing temperatures. ^ Continuous high speed driving and/or severe usage. ^ Crankcase ventilation system restrictions or malfunctioning components. ^ Valve guides and/or valve stem oil seals worn, or the seal omitted. Ream guides and install oversize service valves and/or new valve stem oil seals. ^ Piston rings broken, improperly installed, worn, or not seated properly. Allow adequate time for rings to seat. Replace broken or worn rings as necessary. ^ Piston improperly installed or miss-fitted. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss > Page 1902 Engine Oil: Testing and Inspection Oil Leak Diagnosis Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. Use The Following Steps In Order To Find The Leak: 1. Identify the fluid, determine whether it is engine oil, automatic transmission fluid or power steering fluid. 2. At what point is the fluid leaking from? After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. After a few minutes, you should be able to find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent. Clean the area well, then dry the area. Operate the vehicle for several miles at normal operating temperature and varying speeds. After operating the vehicle, visually check the suspected component. If you still cannot locate the leak, try using the powder or black light and dye method. Perform The Following Steps In Order To Perform The Powder Method: 1. Clean the suspected area. 2. Apply an aerosol-type powder (such as foot powder) to the suspected area. 3. Operate the vehicle under normal operating conditions. 4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source. Perform The Following Steps In Order To Use The Black Light And Dye Method: 1. Pour specified amount of dye into the leaking component. 2. Operate the vehicle under normal operating conditions as directed by the tool manufacturer 3. Direct the light toward the suspect area. The dyed fluid will appear as a yellow path leading to the source. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Testing and Inspection > Page 1903 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications GM Power Steering Fluid P/N 1050017 or Equivalent GM Cold Climate Power Steering Fluid P/N 12345866 or Equivalent Complete System Capacity ................................. ...................................................................................................................................................... 0.70 Liters - 1 1/2 Pints Pump Only ........................................................................................................................................... ..................................................... 0.50 Liters - 1 Pint Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1911 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1912 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1913 Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recharge Equipment File In Section: 01 - HVAC Bulletin No.: 99-01-38-006A Date: May, 2000 WARRANTY ADMINISTRATION Subject: J-43600 ACR 2000 Essential Refrigerant Recovery/Recharge Equipment Models: 1993-2000 Passenger Cars and Light Duty Trucks with R-134a Refrigerant This bulletin is being revised to change the effective date and to update the text. Please discard Corporate Bulletin Number 99-01-38-006 (Section 01 - HVAC). Effective June 1, 2000, the use of J-43600 ACR 2000 will be required on all repairs that require A/C system recovery and are reimbursable by GM. Additionally, GM highly recommends that J-43600 ACR 2000 be used on all GM cars and trucks for customer paid A/C repairs. Important: Also effective June 1, 2000, the "Add" time for all air conditioning recovery is revised to 0.5 hours for front systems and 0.7 hours for front/rear dual systems (RPO C69 or C34). After June 1, 2000, all air conditioning claims submitted with the 0.9 hours "Add" time will be rejected for "labor hours excessive". After the completion of repairs (charging), the ACR 2000 will prompt the user to perform a snapshot of the air conditioning system operating data. The snapshot includes: ^ Maximum high side pressure. ^ Minimum low side pressure. ^ Duct outlet temperatures (2). ^ Refrigerant purity information. This information is captured on a paper printout and in a warranty code. For all GM paid repairs, the paper printout should be attached to the shop copy of the repair order. The warranty code must be submitted in the warranty claim information in the comments field. The code enables the reporting of valuable information about the repair to GM for product quality improvement. Claims submitted without this information may be subject to review and subsequent debit. The required use of J-43600 ACR 2000 raises the question of the acceptable uses for any existing recovery/recycle equipment that GM dealers are currently using. GM recognizes that many of the previously essential ACR4's are reaching the end of their useful life. There are several alternatives for existing equipment that may be considered: ^ Use the existing equipment as customer paid recovery only equipment. Example: Collision repair area. ^ Use the existing equipment as a scavenger unit for contaminated A/C systems. ^ Sell the existing units to repair facilities outside the GM dealer network. ^ Discontinue the use of the existing units if the repair/maintenance costs exceed the value of the equipment. ^ Donate the existing equipment to local technical schools. ^ Dedicate the ACR4 to A/C system flushing, using the J-42939 Flush Adapter. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1914 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ...................................................... 0.68 kg (1.5 lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1917 Refrigerant: Fluid Type Specifications Refrigerant Type R-134a GM P/N 12345922 Or Equivalent Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications The A/C system requires 240 ml (8 fl. oz.) of Polyalkylene Glycol (PAG) refrigerant oil. NOTE: Always refer to underhood label as your primary specification resource. Polyalkylene glycol (PAG) refrigerant oil must be added to the system when components are replaced, as follows: 1. All Compressors (drain and measure the oil). a Drain oil out both the suction and discharge ports of the replacement as well as the old compressor. b. Remove compressor crankcase drain bolt and drain oil from compressor crankcase. - If less than 30 ml (1 oz.) is drained - add 60 ml (2 oz.) to the new compressor. - If more than 30 ml (1 oz.) is drained - add same amount that was drained to the new compressor. c. Install compressor crankcase drain bolt. - Tighten compressor crankcase bolt to 20 N.m (15 lbs. ft.). - Up to 120 ml (4 fluid ounces) of oil can collect in the crankcase. Therefore, it is important when replacing a compressor that the oil in the old compressor crankcase be drained and measured (discard the old oil after recording the amount). 2. Receiver Dehydrator ^ Add 105 ml (3.5 oz.) to receiver dehydrator. 3. Evaporator ^ Add 90 ml (3 oz.) oil. 4. Condenser ^ Add 30 ml (1 oz.) oil. 6. Refrigerant oil loss due to a large leak: ^ If the refrigerant charge is abruptly lost due to a large refrigerant leak, approximately 90 ml (3 oz.) of refrigerant oil will be carried out of the system with the refrigerant. Any failure that causes an abrupt refrigerant discharge will experience this oil loss. Failures that allow the refrigerant to seep or bleed off over time do not experience this oil loss. ^ Upon replacement of a component which caused a large refrigerant leak, add 90 ml (3 oz.) of new polyalkylene glycol (PAG) refrigerant oil plus: the required amount of oil for the particular component (as outlined above). NOTE: Add the oil directly to the replaced component if possible. If the oil cannot easily be added to the replaced part, add the oil to the receiver dehydrator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1924 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Polyalkylene Glycol (PAG) Synthetic Refrigerant Lubricant Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System Brake Bleeding: Service and Repair Bleeding Brake Hydraulic System Scan Tool Method 1. Using a scan tool, select MOTOR REHOME. The motor rehome function cannot be performed if current DTCs are present. If DTCs are present, the vehicle must be repaired and DTCs cleared before performing the motor rehome function. 2. The entire brake system can now be bled. Without Scan Tool NOTE: This method can only be used if the ABS indicator lamp is not illuminated and no DTCs are present. Do not place your foot on the brake pedal through this entire procedure unless specifically directed to do so. 1. Remove foot from brake pedal. 2. Start engine and allow it to run for at least 10 seconds while observing the ABS indicator lamp. 3. If the ABS indicator lamp turned ON and stayed ON after about 10 seconds, a scan tool must be used to diagnose the ABS malfunction. 4. If the ABS indicator lamp turned ON for approximately 3 seconds, then turned OFF and stayed OFF, turn the ignition OFF. 5. Repeat Steps 1 through 4 one more time. 6. The entire brake system can now be bled. General Information WARNING: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. REMOVING AIR FROM THE SYSTEM A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the brake system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipe at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If pipes are disconnected at any fitting located between master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. The time required to bleed the hydraulic system can be reduced if the master cylinder reservoir is filled with brake fluid and as much air as possible is expelled before the master cylinder is installed on the vehicle. Pressure Bleeding Master Cylinder Pressure Bleeding Adapter NOTE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system. 1. Install J 35589 to the master cylinder. 2. Charge J 29532 to 140-172 kPa (20-25 psi). 3. Connect line to J 35589 and open line valve. 4. Raise vehicle and suitably support. 5. If it is necessary to bleed all of the calipers/cylinders, the following sequence should be followed: Right rear Left rear Right front Left front 6. Place a proper size box end wrench (or J 21472) over the caliper/cylinder bleeder valve. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System > Page 1929 7. Attach a clear tube over the bleeder screw. Submerge the other end of the tube in a clear container partially filled with clean brake fluid. 8. Open the bleeder screw at least 3/4 of a turn and allow flow to continue until no air is seen in the fluid. 9. Close the bleeder screw.Tighten Rear bleeder screws to 7 Nm (62 inch lbs.) and Front bleeder screws to 13 Nm (115 inch lbs.) 10. Repeat Steps 6 through 9 until all calipers/cylinders have been bled. 11. Lower vehicle. 12. Check the brake pedal for "sponginess." Repeat entire bleeding procedure to correct either of these two conditions. 13. Remove J 35589 and J 29532. 14. Fill the master cylinder to the proper level. Manual Bleeding Deplete the vacuum reserve by applying, the brakes several times with the ignition "Off". Use extreme care to prevent brake fluid from contacting painted surfaces. 1. Fill the master cylinder reservoir with brake fluid. Maintain the fluid level in the reservoir during the bleeding operation. It is necessary to have an assistant in the vehicle to press on the brake pedal during the manual bleeding procedure. 2. If the master cylinder is known or suspected to have air in the bore, then it must be bled before any wheel cylinder or caliper in the following manner: a. Disconnect the front brake pipe connection(s) at the master cylinder. b. Allow brake fluid to fill the master cylinder until it begins to flow from the front pipe connector port. c. Connect the forward brake pipe(s) to the master cylinder and tighten. d. Depress the brake pedal slowly one time and hold. Loosen the front brake pipe connection at the master cylinder to purge air from the bore. Tighten the connection and then release the brake pedal slowly. Wait 15 seconds. Repeat the sequence, including the 15 second wait, until all air is removed from the bore. Care must be taken to prevent brake fluid from contacting any painted surface. After all air has been removed at the forward connection(s), bleed the master cylinder at the rear (cowl) connection(s) in the same manner as the front. e. If it is known that the calipers and wheel cylinders do not contain any air, then it will not be necessary to bleed them. 3. Individual wheel cylinder or calipers are bled only after all air is removed from the master cylinder. 4. If is necessary to bleed all of the wheel circuits, the following sequence should be followed: 1st - Right rear / 2nd - Left rear / 3rd - Right front / 4th - Left front 5. Raise vehicle.. 6. Place a proper size box end wrench (or special tool) over the caliper/cylinder bleeder valve. 7. Attach a clear tube over the bleeder screw. Submerge the other end of the tube in a clear container partially filled with clean brake fluid. 8. Depress the brake pedal slowly one time and hold. Loosen the bleeder screw to purge air from the cylinder/caliper. Tighten bleeder screw and slowly release pedal. Wait 15 seconds. Repeat the sequence, including the 15 second wait, until all air is removed. It may be necessary to repeat the sequence 10 or more times to remove all the air. Rapid pumping of the brake pedal pushes the master cylinder secondary piston down the bore in a way that makes it difficult to bleed the system. Tighten rear bleeder screws to 7 Nm (62 inch lbs.) and front bleeder screws to 13 Nm (115 inch lbs.) 9. Lower vehicle. 10. Fill the master cylinder to the proper level. 11. Check the brake pedal for "sponginess" or excessive travel. Repeat entire bleeding procedure to correct either of these two conditions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System > Page 1930 Brake Bleeding: Service and Repair Flushing Brake Hydraulic System The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contains the slightest trace of petroleum or mineral based fluids. All rubber parts, including the brake hoses, that have been exposed to contaminated fluid must be replaced. Approximately one quart of fluid is required to flush the hydraulic system. When flushing the system use the steps specified in pressure bleeding procedures shown in "Bleeding Brake Hydraulic System." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel to the straight ahead position. ^ Remove the key from the ignition switch. 1. The AIR BAG fuse from the I/P fuse block. 2. The I/P sound insulator - (LH). 3. The Connector Position Assurance (CPA) and the driver yellow 2-way connector located at the base of the steering column. 4. The Connector Position Assurance (CPA) and the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1935 IMPORTANT With the AIR BAG fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is normal operation and does not indicate a SIR system malfunction. Enabling the SIR System INSTALL OR CONNECT ^ Remove the key from the ignition switch. 1. The passenger yellow 2-way connector and the CPA located near the base of the steering column. 2. The driver yellow 2-way connector and the CPA located at the base of the steering column. 3. The I/P sound insulator - (LH). 4. The AIR BAG fuse to the I/P fuse block. Staying well away from both air bags, turn the ignition switch to the RUN position. Verify that the AIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1936 BAG warning lamp flashes seven times and then stays off. If the AIR BAG warning lamp does not operate as described, perform the SIR DIAGNOSTIC SYSTEM CHECK. See: Restraint Systems/Air Bag Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1937 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn off the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR System prevents deploying of the air bags from the reserve energy supply power. Refer to Disabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1945 Fuse: Locations Engine Compartment Fuse Relay Center LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1946 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1947 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1948 Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block > Page 1949 Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Fuse: Application and ID Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 1952 Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 1953 Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Specifications Fuse Block: Specifications Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Specifications > Page 1957 Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center Fuse Block: Locations Convenience Center RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1960 Fuse Block: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1961 Fuse Block: Locations Engine Compartment Fuse Relay Center LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1962 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1963 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1964 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1965 Fuse Block: Locations RH Upper I/P Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1966 Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1967 LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1968 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1969 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1970 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Convenience Center > Page 1971 LH Side Of Engine Compartment LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Harness Connector Convenience Center: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Harness Connector > Page 1974 Convenience Center: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 1977 Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations Fusible Link: Locations Lower Front Of Engine LH center of engine compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1984 Relay Box: Application and ID Front View Of Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation The Low Coolant Switch is located in the coolant surge tank. The IPC contains the Low Coolant Indicator. The IPC lights this telltale when commanded to by the PCM. If the coolant level in the surge tank is low, the low coolant indicator will turn on and will remain on until the Ignition Switch is turned off or the coolant level in the surge tank is restored to a normal level. For a Bulb Check procedure, the IPC will light this telltale for 3 seconds when the IPC is initially powered up (ignition in "OFF/UNLOCK," "RUN," or "CRANK" positions) regardless of the serial data signal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation The CHECK ENGINE (Malfunction Indicator Lamp) Indicator in the Instrument Panel Cluster. The CHECK ENGINE Indicator will illuminate with the Ignition Switch in "RUN" position and engine off. The light will stay on a short time after the engine starts and should go out in 1 to 5 seconds. If the light stays on, or comes on while driving, service to the emission control system may be required. The indicator is controlled via a hardwired connection with the PCM and the IPC. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation The Check Oil Indicator is controlled by the IPC as commanded by the PCM via serial data. The oil level is monitored by the PCM with an Oil Level Switch. When the PCM determines a low oil condition, it commands the indicator "ON". As a bulb check procedure, the PCM will command this telltale "ON" when the IPC and PCM are powered up (ignition m OFF/UNLOCK," "RUN," or "CRANK" position) and the engine is not running. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair GENERAL VEHICLE LIFTING AND JACKING CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. The additional support will reduce the possibility of the vehicle falling off the hoist. When removing major components from the vehicle while the vehicle is on a hoist, the vehicle frame should be chained to the hoist pads at the same end as the removed components to prevent tip-off. Failure to follow these precautionary measures could result in vehicle damage, serious personal injury, or death. NOTICE: When jacking or lifting a vehicle at prescribed lift points, be certain that lift pads do not contact the exhaust system, brake pipes, cables, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Recalls for Spare Tire: > NHTSA97V106000 > Jun > 97 > Recall 97V106000: Compact Spare Tire Rim Replacement Spare Tire: Recalls Recall 97V106000: Compact Spare Tire Rim Replacement The compact spare tire assemblies were assembled with incorrect rims. If the spare tire is underinflated, the bead can separate from the rim causing a rapid loss of air. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." A rapid loss of air can increase the risk of a vehicle crash. Dealers will replace the rim on the compact spare tire assembly. Owners are requested not to use the spare tire until the rim has been replaced. Owner Notification: Owner notification will begin during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER 1997 PONTIAC SUNFIRE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spare Tire: > NHTSA97V106000 > Jun > 97 > Recall 97V106000: Compact Spare Tire Rim Replacement Spare Tire: All Technical Service Bulletins Recall 97V106000: Compact Spare Tire Rim Replacement The compact spare tire assemblies were assembled with incorrect rims. If the spare tire is underinflated, the bead can separate from the rim causing a rapid loss of air. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." A rapid loss of air can increase the risk of a vehicle crash. Dealers will replace the rim on the compact spare tire assembly. Owners are requested not to use the spare tire until the rim has been replaced. Owner Notification: Owner notification will begin during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER 1997 PONTIAC SUNFIRE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 2013 Spare Tire: Service and Repair All vehicles will be equipped with a high pressure compact spare. The compact spare uses a narrow 4-inch wide rim, although the wheel diameter is usually one inch larger than the road wheels. The compact spare wheel should not be used with standard tires, snow tires, wheel covers or trim rings. If such use is attempted, damage to these items or other parts of the vehicle may occur. The compact spare should be used only on vehicles which offered it as original equipment. CAUTION: To avoid serious personal injury do not stand over tire when inflating. Bead may break when bead snaps over safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 pal) pressure will not seat beads, deflate, lubricate the beads and reinflate. Over-inflation may cause the bead to break and cause serious personal Injury. Inflation pressure of the compact spare must be periodically checked and maintained at 415 kPa (60 psi). It can be mounted and dismounted from its wheel using present tire changing equipment and procedures. As with other tires, the beads should completely seat at 275 kPa (40 psi). The tire may then be safely inflated to 415 kPa (60 psi). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2022 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2023 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2024 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2029 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2035 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2036 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2037 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2042 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2047 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2048 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2053 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2054 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2055 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2060 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2078 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2079 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2080 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2085 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2090 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2091 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2104 Wheels: Specifications Maximum Lateral Runout: Aluminum Wheels ................................................................................................................................ ........................................... 0.76 mm (0.030 inch) Steel Wheels ........................................................ ............................................................................................................................ 1.14 mm (0.045 inch) Maximum Radial Runout: Aluminum Wheels ................................................................................................................................ ........................................... 0.76 mm (0.030 inch) Steel Wheels ........................................................ ............................................................................................................................ 1.01 mm (0.040 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information Wheels: Technician Safety Information WARNING: This vehicle has a Supplemental Inflatable Restraint (SIR) System. Refer to the SIR Component and Wiring Location view in order to determine whether you are performing service on or near the SIR components or the SIR wiring. When you are performing service on or near the SIR components or the SIR wiring, refer to the SIR On-Vehicle Service information. Failure to follow the WARNINGS could cause air bag deployment, personal injury, or unnecessary SIR system repairs. WARNING: To help avoid personal Injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle slipping from the hoist. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information > Page 2107 Wheels: Vehicle Damage Warnings NOTICE: Always use the correct fastener in the correct location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > General Information Wheels: Description and Operation General Information The factory installed tires and wheels are designed to operate with loads up to and including the full rated load capacity when inflated to the recommended inflation pressures. Correct tire pressures, wheel alignment and driving techniques have an important influence on tire life. Heavy cornering, excessive rapid acceleration, and heavy braking will increase tire wear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > General Information > Page 2110 Wheels: Description and Operation Wheels Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, leak air through welds, have elongated bolt holes, if wheel nuts won't stay tight, or if they are heavily rusted. Wheels with excessive runout may cause objectional vibrations. Replacement wheels must be equivalent to the original equipment wheels in load capacity, diameter, rim width, offset, and mounting configuration. A wheel of improper size or type may affect wheel and bearing life, brake cooling, speedometer/odometer calibration, vehicle ground clearance, and tire clearance to the body and chassis. Steel wheels can be identified by a two or three-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, part number, and manufacturer ID cast into their back side. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 2111 Wheels: Testing and Inspection Wheel runout should be measured with an accurate dial indicator. Measurements may be taken with the wheel installed on the vehicle, or off the vehicle using an accurate mounting surface such as on a wheel balancer. Measurements may also be taken with or without the tire mounted on the wheel. Radial runout and lateral runout should be measured on both the inboard and outboard rim flanges. With the dial indicator firmly in position, slowly rotate the wheel one revolution and record the total indicator reading. If any measurement exceeds specifications, and there is a vibration that wheel balancing will not correct, the wheel should be replaced. Disregard any indicator readings due to welds, paint runs, scratches, etc. ^ STEEL WHEELS - Radial runout 1.01 mm (0.040 inch) - Lateral runout 1.14 mm (0.045 inch) ^ ALUMINUM WHEELS - Radial runout 0.76 mm (0.030 inch) - Lateral runout 0.76 mm (0.030 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service Wheels: Service and Repair On-Vehicle Service Wheel Removal GENERAL INFORMATION Penetrating oil has not been found to be effective in removing tight wheels. However, if it is used, it should be applied sparingly to the wheel center hole area only. CAUTION: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum, It could cause the wheel to work loose as the vehicle Is driven, resulting in a loss of control and an injury accident. Never use heat to loosen-a tight wheel. It can shorten the life of the wheel, studs or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the proper fastener tightening specification to avoid bending the wheel or rotor. Sometimes wheels can be difficult to remove due to foreign material or a tight fit between the wheel center hole and the rotor. Excessive force such as hammering the wheel or tire can cause damage and is not recommended. Slight tapping on the tire sidewall using a large rubber mallet is acceptable. The wheel can be removed without damage as follows: 1. Tighten all wheel nuts on the affected wheel. Then loosen each nut two turns. Rock the vehicle side to side. If this is not effective, go to step 2. Rock the vehicle from "DRIVE" to "REVERSE" allowing the vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal to loosen the wheel. If the wheel still does not free up, then rock the vehicle again from side to side as hard as possible using one or more persons' body weight. If the wheel is still tight, repeat the procedure. REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Wheel cover, if equipped. 3. Wheel nuts. ^ Mark location of tire and wheel assembly to hub assembly. ^ Clean wheel nuts, studs and the wheel and brake drum or rotor mounting surfaces. CAUTION: Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface and brake drum or rotor by scraping and wire brushing. Installing wheels without good metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen, which may later allow the wheel to come off while the vehicle is in motion. Wheel Installation INSTALL OR CONNECT 1. Hub cap on aluminum wheel, if removed. 2. Tire and wheel assembly. ^ Align locating mark of tire and wheel to hub assembly. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener tightening specification and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. CAUTION: Never use oil or grease on studs or nuts. Tighten the wheel nuts with your fingers until they are snug. Then, tighten the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 2114 nuts (in the sequence shown) to the fastener tightening specification shown in "Specifications". Improperly tightened wheel nuts could eventually allow the wheel to come off while the vehicle is moving, possibly causing loss of control, personal injury and property damage. 3. Wheel nuts. ^ Tighten wheel nuts in sequence to 140 Nm (100 ft. lbs.). 4. Wheel cover, if equipped. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 2115 Wheels: Service and Repair Aluminum Wheels - Additional Information Aluminum Wheel Hub Cap REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Tire and wheel assembly. 3. Hub cap. ^ Place a block of wood approximately 50 mm (2 inches) in diameter with a squared off end against the back surface of the cap. A sharp hammer blow on the block of wood will remove the cap. INSTALL OR CONNECT 1. Hub cap ^ Place cap into position at wheel opening and place a block of wood at least 75 mm (3 inches) on diameter against cap face. Install cap by striking block of wood with hammer. NOTICE: Failure to hit cap squarely without the load distributed evenly could result in permanent damage to the cap. 2. Tire and wheel assembly. Aluminum Wheel Porosity Repair 1. Raise vehicle and suitably support. 2. Remove tire and wheel assembly. 3. Locate leaking areas by inflating tire to 275 kPa (40 psi) and dipping tire and wheel assembly into a water bath. 4. Mark leak areas and remove tire from wheel. 5. Scuff inside rim surface at leak area with 80 number grit sandpaper and clean area with general purpose cleaner such as 3M P/N 08984 or equivalent. 6. Apply 3 mm (1/8 inch) thick layer of adhesive/sealant P/N 1052366 or equivalent to leak area and allow six hours of drying time. CAUTION: To avoid serious personal injury, do not stand over tire when inflating. Bead may break when bead snaps over safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat beads, deflate, lubricate the beads and reinflate. Over-inflation may cause the bead to break and cause serious personal Injury. 7. Mount tire on wheel, pressurize to 275 kPa (40 psi) and check for leaks. 8. Adjust tire pressure to meet specifications. 9. Balance tire and wheel assembly. 10. Install tire and wheel assembly. Aluminum Wheel Refinishing GENERAL PROCEDURE A protective clear or color coating is applied to the surface of original equipment cast aluminum wheels. A surface degradation condition can begin to develop if this clear coating is damaged or removed. This can happen at some automatic car wash facilities using aggressive silicon carbide tipped tire brushes to clean white walls and tires. Once the protective coating is damaged, exposure to caustic cleaners and/or road salt further causes surface degradation. The following procedure details how to strip, clean and coat aluminum wheels that are affected by these conditions. ^ Required Materials: - Amchem Alumi Prep number 33 - stock number DX533 or equivalent - cleaning and conditioning chemical for aluminum. - Amchem Alodine number 1001 - stock number DXSOT or equivalent - coating chemical for aluminum. - Ditzler Delclear Acrylic Urethane Clear - stock number DAU-75 or equivalent. - Ditzler Delthane Ultra-Urethane Additive - stock DXR-80 or equivalent. INITIAL PREPARATION Remove Or Disconnect 1. Wheel and tire assembly from the vehicle. ^ Match mark tire for reinstallation of outboard wheel weights after re-coating of wheel. 2. Outboard wheel weights. ^ Clean wheel inside and out with a water base all purpose cleaner. Remove grease or oil with a solvent cleaner. ACCENT COLOR PREPARATION Sand over painted areas that do not require recoloring with number 400 grit (wet or dry) to promote adhesion of clear coat. SURFACE DAMAGE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 2116 CAUTION: Do not use vehicle power to rotate the wheel while sanding or personal injury may result. 1. Mount tire and wheel on brake lathe and spin slowly. NOTICE: Do not use abrasive coarser than 80 grit or wheel may be damaged. 2. Sand wheel with backing block or pad by holding abrasive flat to surface of wheel and moving slowly back and forth from center to outer edge to remove damage. Use the following sandpaper grits in the order listed. A. Sand with number 80 grit sandpaper. B. Sand with number 150 grit sandpaper. C. Sand with number 240 grit sandpaper. 3. Continue with "Re-coating Procedure." CLEAR COAT DAMAGE ON UNPAINTED WHEELS CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal Injury. 1. Apply chemical stripper. ^ Allow stripper to penetrate coating. ^ Use small 1/4 inch detail brush dipped in stripper to apply material around perimeter and spoke-like areas. 2. Remove stripper following manufacturers recommendations. CAUTION: Do not use vehicle power to rotate the wheel while sanding or personal injury may result. 3. Sand wheel with 240 grit while rotating wheel on a slow spinning brake lathe or by mounting on vehicle and spinning by hand. This will restore the machined appearance and promote adhesion. 4. Continue with "Re-coating Procedure." RE-COATING PROCEDURE CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal Injury. 1. Clean surface of contaminants by washing with soap and water. 2. Spray the wheel with Amchem number 33 or equivalent. ^ Let the wheel soak for 1 to 3 minutes. ^ Rinse the wheel with water and blow dry. 3. Soak wheel with Amchem #1001 or equivalent. ^ Let the wheel soak for 1 to 3 minutes. ^ Rinse the wheel with water and blow dry. 4. Mask off the tire. CAUTION: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 5. Finish the wheel with Ditzler Delclear Acrylic Urethane and Ditzler Ultra-Urethane Additive or equivalent using three coats. Refer to labels for specific directions. ^ First Coat - Light mist coat, let flash. ^ Second Coat Light, let flash. ^ -Third Coat - Heavy double wet coat. 6. Let the wheel dry for 24 hours - (or flash for 30 minutes, force dry at 60° C (140° F) for 30 minutes, and allow to cool for 30 minutes before mounting. INSTALL OR CONNECT 1. Balance wheel and tire assembly. ^ Replace the original balance weights with nylon coated weights to avoid discoloration of the wheel. 2. Tire and wheel assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 2117 Wheels: Service and Repair Wheel Repair Wheel repairs that use welding, heating, or peening are not approved. An inner tube is not an acceptable repair for leaky wheels or tires. Porosity in aluminum wheels can be repaired, refer to "Aluminum Wheel Porosity Repair." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 2118 Wheels: Service and Repair Balancing Tire and Wheel GENERAL INFORMATION There are two types of tire and wheel balancing, static and dynamic. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called wheel tramp. This condition may eventually cause uneven tire wear Dynamic balance is the equal distribution of weight on each side of the centerline so that when the assembly spins there is no tendency for it to move from side to side. Assemblies that are dynamically unbalanced may cause wheel shimmy. GENERAL BALANCE PRECAUTIONS Deposits of foreign material must be cleaned from the inside of the wheel. When balancing aluminum and composite wheels the balancer pressure cup should have a protective plastic or rubber edge on it to avoid damaging the rim surface finish. Stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain a good balance. The tire should be inspected for any damage, then balanced according to the equipment manufacturer's recommendations. OFF-VEHICLE BALANCING Wheel balancing should be performed using an electronic off-vehicle balancer. They are easy to use and give both a static and a dynamic balance. Although they do not correct for drum or rotor unbalance as does on-vehicle spin balancing, this is overcome by their accuracy (usually to within 1/8 ounce). When balancing off-vehicle, the wheel should locate on the balancer with a cone through the back side of the center pilot hole (not by the wheel stud holes). ON-VEHICLE BALANCING Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 2119 When needed, on-vehicle balancing will help correct vibrations due to brake drum, rotor, and wheel cover imbalance. The front suspension should not be allowed to hang free. When the CV joint is run at a very high angle, extra vibrations can occur, resulting in damage to boots and joints. Always follow the equipment manufacturer's instructions. When balancing on-vehicle, do not remove the balance weights from the off-vehicle dynamic balance. If more than one ounce of additional weight is required, it should be split between the inner and outer rim flange. NOTICE: The driven tire and wheel assemblies should be spun using the engine. Limit speed as stated in the following Caution. CAUTION: Do not spin the drive wheels faster than 55 km/h (35 mph) as indicated by the speedometer. This limit is necessary because the speedometer indicates only one-half of the actual wheel speed when one drive wheel is spinning and the other drive wheel is stopped. Personal injury and damage may result from high speed spinning. WHEEL BALANCE WEIGHTS When static balancing, if more than 40 grams (1.0 oz.) are needed, the wheel weights should be split as equal as possible between the inboard and outboard flanges. Balancing factory aluminum wheels requires the use of special nylon coated clip-on wheel weights. These weights are designed to fit over the thicker rim flange of the aluminum wheel and should be installed with a plastic tipped hammer. Adhesive wheel weights are also available. Use the following procedure to install adhesive wheel weights. ADHESIVE WHEEL WEIGHT INSTALLATION 1. Clean wheel by sanding to bare aluminum where wheel weight is to be located. 2. Wipe wheel weight attachment area with a mixture of half Isopropyl alcohol and half water. A clean cloth or paper towel must be used for this operation. 3. Dry the attachment area with hot air. Surface of wheel should be warm to the touch. 4. The adhesive backing on wheel weights must be warmed to room temperature. 5. Remove tape from back of weights. Do not touch the adhesive surface. 6. Apply wheel weight and press on with hand pressure. 7. Secure wheel weight with a 70-110 N (16-25 lbs.) force applied with a roller. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2123 Wheel Bearing: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2124 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension FRONT WHEEL BEARINGS AND/OR HUB ^ Tools Required: J 28733-A Front Hub Spindle Remover REMOVE OR DISCONNECT 1. Drive axle. 2. Brake caliper bolts, and support caliper. 3. Rotor. 4. Hub and bearing assembly. 5. Hub and bearing assembly from steering knuckle. 6. Hub and bearing. INSTALL OR CONNECT 1. Hub and bearing assembly to steering knuckle. 2. Hub and bearing assembly bolts. ^ Tighten hub and bearing assembly bolts to 95 Nm (70 ft. lbs.). 3. Rotor. 4. Brake caliper and bolts. 5. New hub and bearing into steering knuckle. 6. Drive axle. 7. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 2127 Wheel Bearing: Service and Repair Rear Suspension REAR WHEEL BEARINGS AND/OR HUB REMOVE OR DISCONNECT 1. Raise vehicle. 2. Wheel and tire assemblies. 3. Brake drum. NOTICE: Do not hammer on brake drum as damage to the assembly could result. 4. Rear ABS wheel speed sensor wire connector. 5. Remove hub and bearing assembly from axle. The top rear attaching bolt/nut will not clear the brake shoe when removing the hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. INSTALL OR CONNECT 1. Connect rear ABS wheel speed sensor wire connector. 2. Hub and Bearing assembly. Position top rear attaching bolt in hub and bearing assembly prior to the installation in the axle assembly. ^ Tighten hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). 3. Brake drum. 4. Wheel and tire assembly. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Tire and wheel assembly. 3. Hub cap. ^ Place a block of wood approximately 50 mm (2 inches) in diameter with a squared off end against the back surface of the cap. A sharp hammer blow on the block of wood will remove the cap. INSTALL OR CONNECT 1. Hub cap ^ Place cap into position at wheel opening and place a block of wood at least 75 mm (3 inches) on diameter against cap face. Install cap by striking block of wood with hammer. NOTICE: Failure to hit cap squarely without the load distributed evenly could result in permanent damage to the cap. 2. Tire and wheel assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Steering - Various Revised Tightening Specifications Axle Nut: Technical Service Bulletins Steering - Various Revised Tightening Specifications CHEVROLET 73-32-03A Issued: 05/01/97 SMU - SECTIONS 3B/3C/4D REVISION: 04/11/97 THIS BULLETIN IS BEING REVISED TO UPDATE THE DRIVE AXLE NUT TIGHTENING SPECIFICATIONS FOR THE N CAR. PLEASE DISCARD CORPORATE BULLETIN NUMBER 73-32-03 (SECTION 3 - STEERING/SUSPENSION). SUBJECT: SERVICE MANUAL UPDATE - SECTIONS 3B/3C/4D - REVISED TIGHTENING SPECIFICATIONS MODELS: 1997 CHEVROLET CAVALIER, MALIBU 1997 OLDSMOBILE CUTLASS 1997 PONTIAC SUNFIRE THIS BULLETIN IS BEING ISSUED TO REVISE THE TIGHTENING SPECIFICATIONS IN SECTIONS 3B, 3C AND 4D OF THE SERVICE MANUAL AS FOLLOWS: J CAR SECTIONS 3B-8, 3B-9, 3C-5 AND 3C-13: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 90 DEGREE ROTATION. N CAR SECTIONS 3C-6 AND 3C-16: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 180 DEGREE ROTATION. SECTION 3B-12: THE CORRECT TIGHTENING SPECIFICATIONS ARE AS FOLLOWS: - STEERING COLUMN LOWER PINCH BOLT 22 N.M (16 LB FT) - STEERING COLUMN UPPER PINCH BOLT 22 N.M (16 LB FT) SECTIONS 3C-16, 4D-4 AND 4D-5: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - FRONT DRIVE AXLE NUT 385 N.M (284 LB FT) +/- 5 N.M (44 LB IN). REPLACE THE DRIVE AXLE NUT WITH A NEW ONE AFTER EVERY REMOVAL. NEVER RE-USE THE DRIVE AXLE NUT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 2136 Axle Nut: Specifications Service Manual Update # 73-32-03A Drive Axle Nut (New) ............................................................................................................................................... 385 Nm (284 lb ft) +/- 5 Nm (44 lb in) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2145 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2151 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2157 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2158 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2159 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2165 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2166 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2167 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque Wheel Fastener: Specifications Tightening Torque All Wheels Nuts ................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque > Page 2170 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Application and ID > Metric Wheel Nuts and Bolts Wheel Fastener: Application and ID Metric Wheel Nuts and Bolts All models use metric wheel nuts and wheel studs. The nut will have the word "metric" stamped on the face and the stud will have the letter "M" stamped into the threaded end. The word "metric" is stamped on the head. The thread size of the metric wheel nuts and wheel studs are "M 12 x 1.5". This signifies: M = Metric 12 = Diameter in millimeters 1.5 = Millimeters per thread If a broken stud is found, refer to "Front Suspension" or "Rear Suspension" for replacement procedure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Application and ID > Metric Wheel Nuts and Bolts > Page 2173 Wheel Fastener: Application and ID Metric Wheel Nuts and Studs All models use metric wheel nuts and wheel studs. The nut will have the word "metric" stamped on the face and the stud will have the letter "M" stamped into the threaded end. The word "metric" is stamped on the head. The thread size of the metric wheel nuts and wheel studs are "M 12 x 1.5". This signifies: M = Metric 12 = Diameter in millimeters 1.5 = Millimeters per thread If a broken stud is found, refer to "Front Suspension" or "Rear Suspension" for replacement procedure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension ^ Tools Required: J 6627-A Wheel Stud Remover - J 28733-A Front Hub Spindle Remover. - Or Equivalents REMOVE OR DISCONNECT 1. Hub and bearing assembly. 2. Wheel stud from hub and bearing assembly using tool J 6627-A. Discard stud. INSTALL OR CONNECT 1. New wheel stud into hub and bearing assembly. 2. Flat washers and nut (flat side down) onto wheel stud, and tighten until wheel stud is fully seated. 3. Hub and bearing assembly. 4. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2176 Wheel Fastener: Service and Repair Rear Suspension ^ Tool Required: J 6627-A Wheel Stud Remover - Or Equivalent REMOVE OR DISCONNECT 1. Wheel and tire assembly. 2. Brake drum. NOTICE: Do not hammer on brake drum as damage to the bearing or deformation of the drum could result. 3. Wheel stud using tool J 6627-A. 4. Discard stud. INSTALL OR CONNECT 1. New stud (insert from back side of hub). 2. Four flat washers on stud. 3. Wheel nut (install with flat side toward washers). 4. Tighten nut until stud head is properly seated in hub flange. 5. Remove nut and washers. 6. Brake drum. 7. Wheel and tire assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2181 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2182 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2183 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2184 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2185 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 2186 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair GENERAL VEHICLE LIFTING AND JACKING CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. The additional support will reduce the possibility of the vehicle falling off the hoist. When removing major components from the vehicle while the vehicle is on a hoist, the vehicle frame should be chained to the hoist pads at the same end as the removed components to prevent tip-off. Failure to follow these precautionary measures could result in vehicle damage, serious personal injury, or death. NOTICE: When jacking or lifting a vehicle at prescribed lift points, be certain that lift pads do not contact the exhaust system, brake pipes, cables, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Dimensions/Clearance Camshaft Bearing: Specifications Dimensions/Clearance Camshaft Bearing I.D. No. 1 .................................................................................................................................................... ........... 40.00-40.040 mm (1.5748-1.5764 inches) No. 2-5 ............................................................................................................................................................ 35.00-35.040 mm (1.3780-1.3795 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Dimensions/Clearance > Page 2200 Camshaft Bearing: Specifications Camshaft Bearing Cap Torque Tighten the camshaft housing cover to camshaft housing bolts to 15 Nm (11 ft. lbs.) + 30 degrees. Rotate the bolts the amount of degrees specified in sequence. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Cam Gear Torque Specifications Camshaft Gear/Sprocket: Specifications Cam Gear Torque Specifications Camshaft Sprocket Retaining Bolt ............................................................................................................................................................ 70 Nm (52 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Cam Gear Torque Specifications > Page 2205 Camshaft Gear/Sprocket: Specifications Tightening Camshaft Sprocket to the Camshaft Bolt .................................................................................................................................................. 70 Nm (52 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation Camshaft Gear/Sprocket: Service and Repair Installation NOTE: GM does not provide timing chain timing marks, or information to perform timing chain service without the special tools shown in this procedure. TOOL REQUIRED ^ J 36800 Camshaft Sprocket Timing Alignment Pin ^ J 39579 Camshaft Sprocket Wrench CAUTION: Failure to follow this procedure could result in severe engine damage. 1. Install the intake camshaft sprocket onto the camshaft with the marked surface showing. 2. Install the intake camshaft sprocket Retaining bolt and washer. Tighten the bolt to 70 Nm (52 ft. lbs.) while holding the sprocket with the camshaft sprocket wrench. 3. Use Adhesive/Sealant Compound GM P/N 12345493 or equivalent on the camshaft sprocket bolt. 4. Install the camshaft sprocket timing alignment pin through the holes in the camshaft sprockets into the holes in the timing chain housing in order to position the camshaft for correct timing. 5. If the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins, use the following procedure: a. The crankshaft must be rotated 90 degrees clockwise off of the TDC in order to give the valves adequate clearance to open. b. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to the top dead center. WARNING: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. NOTE: The side of the timing chain that was marked during removal must be showing when the chain is installed. 6. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2208 7. Set the camshaft sprockets at the timed position and use the following procedure in order to install the timing chain: a. Remove the alignment dowel pin from the intake camshaft. b. Use the camshaft sprocket wrench in order to rotate the intake camshaft sprocket counter clockwise enough to slide the timing chain over the intake camshaft sprocket. c. Release the camshaft sprocket wrench. The length of the chain between the two camshaft sprockets will tighten. d. If properly timed the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 8. Leave the alignment dowel pins installed. 9. Raise and support the vehicle. 10. With the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and the recheck marks. 11. In order to reload the timing chain tensioner assembly to its zero position, form a keeper from a piece of heavy gauge wire. 12. Apply a slight force on the tensioner blade in order to compress the plunger. 13. Insert a small screwdriver into the reset access hole, and pry the ratchet pawl away from the ratchet teeth while forcing the plunger completely in the hole. 14. Install the keeper between the access hole and the blade. 15. Install the tensioner assembly to the chain housing. Recheck the plunger assembly installation, it is correctly installed when the long end is toward the crankshaft. 16. Install the timing chain tensioner bolts. Tighten the bolts to 10 Nm (89 inch lbs.). 17. Lower the vehicle enough to reach and remove the alignment dowel pins. 18. Rotate the crankshaft clockwise (normal rotation) two full rotations. 19. Align the crankshaft keyway with the mark on the cylinder block and reinstall alignment dowel pins. 20. Alignment dowel pins will slide in easily if the engine is timed correctly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2209 21. Install the timing chain guides. 22. Install the engine front cover. 23. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2210 Camshaft Gear/Sprocket: Service and Repair Removal NOTE: GM does not provide timing chain timing marks, or information to perform timing chain service without the special tools shown in this procedure. ^ Tools Required, or equivalent: J 36800 Camshaft Sprocket Timing Alignment Pin J 39579 Camshaft Sprocket Wrench NOTE: Before removing the timing chain, read the entire procedure. The timing chain and the crankshaft sprocket must be marked in order to insure reassembly with the same side facing out at the time of reassembly. CAUTION: The timing chain is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. 1. Disconnect the negative battery cable. 2. Remove the engine front cover. 3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes line up with the holes in the timing chain housing. 4. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the "Timed" position. 5. Remove the timing chain guides. 6. Raise and support the vehicle. 7. Ensure that all of the slack in the timing chain is above the tensioner assembly. 8. Remove the timing chain tensioner. 9. The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward. CAUTION: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur. 10. If difficulty is encountered in removing the timing chain tensioner shoe, use the following procedure in order to remove the intake camshaft sprocket. a. Lower the vehicle. b. Hold the intake camshaft sprocket with the camshaft sprocket wrench and remove the sprocket bolt and washer. c. Remove the washer from the bolt and rethread the bolt back into the camshaft by hand (the bolt provides a surface to push against). d. Remove the intake camshaft sprocket. Use a three-jaw puller in the three relief holes in the sprocket. 11. Remove the tensioner assembly retaining bolts and tensioner. CAUTION: The timing chain and the crankshaft sprocket must be marked prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2211 12. Mark the crankshaft sprocket and the timing chain outer surface. 13. Remove the timing chain. 14. Clean the old sealant off of the bolt with a wire brush. 15. Clean the threaded hole in the camshaft with a round nylon bristle brush. 16. Inspect the parts for wear and replace the parts as necessary. Some scoring of the timing chain shoe and the guides is normal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > General Camshaft: Specifications General Lobe Lift Intake .................................................................................................................................... .............................................. 9.0 mm (0.354 inches) Exhaust ............................................................ ................................................................................................................................... 8.8 mm (0.356 inches) Journal Diameter: No. 1 .................................................................................................................................................... .............. 39.93-39-95 mm (1.5720-1.5728 inches) No. 2-5 ................................................................ ............................................................................................... 34.93-34.95 mm (1.3751-1.3760 inches) Journal Clearance ................................................................................................................................................... 0.050-0.110 mm (0.0019-0.0043 inches) End Play Clearance ................................................................................................................................................ 0.025-0.225 mm (0.0009-0.0088 inches) Lobe Taper ............................................................................................................................................................. 0.046-0.083 mm (0.0018-0.0033 inches) On Diameter in ................................................................... ............................................................................................................ 14.0 mm (0.5512 inches) Lifter Bore I.D. ................................................................................................................................................ 33.989-34.019 mm (1.3381-1.33393 inches) Lifter O.D. ......................................................................................................................................................... 33.959-33.975 mm (1.3369-1.3375 inches) Lifter to Bore Clearance ...................................................................................................................................... 0.016-0.058 mm (0.00006-0.0023 inches) Lip Seal Bore I.D. .............................................................................................................................................. 49.975-50.025 mm (1.9675-1.9695 inches) Lip Seal O.D. ..................................................................................................................................................... 49.975-50.025 mm (1.9675-1.9695 inches) Cam Carrier Flatness ..................................................... ................................................................................................................. 0.07 mm (0.0028 inches) Bottom Maximum [1] ............................................................................................................................ ......................................... 0.025 mm (0.001 inches) [1] Within 100.0 mm (3.937 inches). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > General > Page 2216 Camshaft: Specifications Tightening Camshaft (exhaust) Rear Cover ........................................................................................................................................................... 14 Nm (124 inch lbs.) Camshaft Position Sensor Bolt .............................................................................................................................................................. 10 Nm (89 inch lbs.) Pipe Bracket To the Camshaft Housing .......................................................................................................................................... 15 Nm (11 ft. lbs.) + 30° Fuel Rail to the Camshaft Housing ........................................................................................................................................................... 26 Nm (19 ft. lbs.) Ignition Coil/Module To Camshaft Housings ........................................................................................................................................... 22 Nm (16 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2217 Camshaft: Description and Operation Two camshafts are used, one for all intake valves, the other for all exhaust valves. The camshafts are cast iron. The intake camshaft had a pressed-in hex insert. The hex inset is used to drive the direct drive power steering pump. The intake camshaft also has the camshaft position sensor lobe cast onto it. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation Camshaft: Service and Repair Exhaust - Installation ^ Tools Required J 36660 Torque Angle Meter, or equivalent. 1. Install the camshaft housing to the cylinder head with a new gasket. Sealer is unnecessary. 2. Loosely install one camshaft housing to the cylinder head bolt in order to hold the housing in place. NOTE: Used lifters must be returned to their original position in the camshaft housing. If the camshaft is being replaced, the lifters must also be replaced. 3. Install the lifters into the lifter bores. CAUTION: The camshaft lobes and the journals must be adequately lubricated or serious engine damage will occur upon start up. 4. Lube the camshaft lobes and the journals with the Camshaft and Lifter Prelube GM P/N 12345501 or the equivalent. 5. Install the camshaft in the same position as when removed. The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores. 6. Install the new camshaft housing to the orange camshaft housing cover seals into the cover. Sealer is unnecessary. 7. Remove the bolt holding the housing in place. 8. Apply pipe sealant GM P/N 1052080 or the equivalent to the camshaft housing and the cover retaining bolt threads. 9. Install the camshaft housing cover to the camshaft housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2220 10. Use the torque angle meter, in order to install the bolts. ^ Tighten the camshaft housing to cylinder head bolts to 15 Nm (11 ft. lbs.) + 90 degrees. ^ Tighten the camshaft housing cover to camshaft housing bolts to 15 Nm (11 ft. lbs.) + 30 degrees. 11. Install the timing chain housing to camshaft housing and the timing chain. Refer to Timing Chain Housing Replacement. 12. Install the exhaust camshaft housing cover and the new gasket. 13. Install the transmission fluid level indicator tube assembly to the exhaust camshaft cover. 14. Install the electrical connection to the oil pressure switch. 15. Reinstall any spark plugs boot connector assembly that stuck to a spark plug, back onto the ignition coil module assembly. 16. Locate the ignition coil and the module assembly over the spark plugs. 17. Push straight down. 18. Clean any lubricant that is present on the ignition coil and the module assembly to the camshaft housing bolts. 19. Apply Pipe Sealant GM P/N 1052080 or the equivalent onto the ignition coil and the module assembly to the camshaft housing bolts. Tighten the bolts to 15 Nm (11 ft. lbs.) + 30 degrees. 20. Install the electrical connector to the ignition coil and the module assembly. 21. Connect the negative battery cable. NOTE: Do not compress the lifter plungers using a vise or other tool. This will cause more air to enter the lifter assembly and will take more time to bleed out once the lifters are installed. 22. If new lifters have been installed or the lifters bled down while the engine was disassembled excessive lifter noise may be experienced. This is a normal condition and no engine damage is occurring. Use the following procedure in order to purge the air from the lifters: a. Start the engine and allow to warm up at the idle for 5 minutes. b. Increase the engine speed to 2000 RPM until the lifter noise is gone. c. Return the engine to idle for an additional 5 minutes or perform a road test. 23. Start the engine and inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2221 Camshaft: Service and Repair Exhaust - Removal ^ Tools Required J 36011 Spark Plug Connector Assembly Remover, or equivalent. NOTE: Any time the camshaft housing to cylinder head bolts are loosened or removed, the camshaft housing to cylinder head gasket must be replaced. During disassembly, ensure that the valve lifters are kept together and identified so that they can be reinstalled in the original locations. Before disassembling the valve mechanism, make a compression test and note the results. 1. Disconnect the negative battery cable. 2. Remove the ignition coil and the module assembly electrical connection. 3. Remove the ignition coil and the module assembly to the camshaft housing bolts and remove the assembly by pulling straight up. 4. Use the spark plug connector assembly remover in order to remove the connector assembly if stuck to the spark plugs. Use the tool by first twisting then pulling upward on the connector assembly. 5. Remove the electrical connection from the oil pressure switch. 6. For vehicles equipped with automatic transmission, remove the transmission fluid level indicator tube assembly from the exhaust camshaft cover and the position aside. 7. Disconnect the timing chain housing at the exhaust camshaft housing but do not remove from the parts from the vehicle. 8. Remove the exhaust camshaft cover and the gasket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2222 9. Remove the exhaust camshaft housing to the cylinder head bolts. 10. Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts. 11. Leave two bolts loosely in place in order to hold the camshaft housing while separating the camshaft cover from the housing. CAUTION: Tighten the bolts in evenly in order to prevent the cover from binding on the dowel pins. 12. Push the cover off the housing by threading the four of the housing to head retaining bolts into the tapped holes in the camshaft cover. 13. Remove the two loosely installed camshaft housing to head bolts. 14. Remove the cover. 15. Discard the gaskets. 16. Loosely reinstall the one camshaft housing to the cylinder head bolt in order to retain the housing during the camshaft and the lifter removal. 17. Notice the position of the chain sprocket dowel pin for reassembly. Remove the camshaft carefully in order to prevent damage to the camshaft or the journals. 18. Remove the valve lifters. Keep the lifters in order so that the lifters can be reinstalled in the original location. NOTE: These lifters are not serviceable. Replace any faulty lifters. Coat the lifter with Camshaft and Lifter Prelube GM P/N 12345501 or the equivalent. If new lifters are installed, add the Engine Oil Supplement GM P/N 1052367 or the equivalent to the engine oil. 19. In order to minimize lifter bleed down, use the following procedure: ^ Store lifters upside down (the camshaft contact surface down) on a level surface. ^ Store the lifters submerged in clean engine oil. NOTE: Ensure that the camshaft housing alignment dowel pins are in the cylinder head prior to installing the housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2223 20. Remove the camshaft housing gasket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2224 Camshaft: Service and Repair Housing Oil Gallery Plugs REMOVAL PROCEDURE ^ Tools Required J 37868 Oil Gallery Plug Installer, or equivalent. 1. Disconnect the negative battery cable. 2. Remove the camshaft housing. 3. Disassemble the oil gallery plug as follows: a. Using a 8.33 mm (21/64 inches) bit, drill the oil gallery plug. b. With a 10.0 mm (0.3937 inches) bottoming tap, thread the plug. c. Install a 10.0 mm bolt into the plug and pull the plug out. 4. Clean the oil gallery plus hole. INSTALLATION PROCEDURE 1. Assemble the oil gallery plug with the oil gallery plug installer. 2. Install the camshaft housing. 3. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2225 Camshaft: Service and Repair Intake - Installation ^ Tools Required J 36660 Torque Angle Meter, or equivalent. 1. Install the camshaft housing to the cylinder head with a new gasket. Sealer is unnecessary. 2. Loosely install on camshaft housing to the cylinder head bolt in order to hold the housing in place. CAUTION: The camshaft lobes and the journals must be adequately lubricated or serious engine damage will occur upon start up. NOTE: Used lifters must be returned to the original position in the camshaft housing. If the camshaft is being replaced, the lifters actuated by the camshaft must also be replaced. 3. Install the lifters into the lifter bores. 4. Install the camshaft in the same position as when removed. The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores. 5. Install the new camshaft housing to the green colored camshaft housing cover seals and into the cover. Sealant is unnecessary. 6. Remove the bolt holding the housing in place. 7. Apply the pipe sealant GM P/N 1052080 or the equivalent to the camshaft housing and the cover retaining bolt threads. 8. Install the camshaft housing cover to the camshaft housing. NOTE: The top intake camshaft housing bolts are tightened to a different specification than the other camshaft housing bolts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2226 9. Using the torque angle meter, install and tighten the bolts. ^ Tighten the camshaft housing to cylinder head bolts to 15 Nm (11 ft. lbs.) + 90 degrees. ^ Tighten the camshaft housing cover to camshaft housing bolts to 15 Nm (11 ft. lbs.) + 30 degrees. 10. Rotate the bolts the amount of degrees specified in sequence. 11. Install the timing chain housing and the timing chain. 12. Uncover the fuel injectors and install the new injector O-ring seals. Lubricate the O-ring seals with engine oil. 13. Uncover the injector openings in the cylinder head and install the fuel rail onto the cylinder head. 14. Install the fuel rail to the camshaft housing bolts. Tighten the camshaft housing bolts to 26 Nm (19 ft. lbs.). 15. Install the fuel line retaining clamp and the retainer to the bracket on top of the camshaft housing. 16. Install the vacuum line to the fuel pressure regulator. 17. Install the fuel injector harness connector. 18. Install the camshaft position sensor connector. NOTE: When reinstalling the power steering pump, apply a 3 mm bead of GM P/N 12346286 sealer or the equivalent to the joint at the end of the camshaft housing halves before the installation of the power steering pump and the pump face seal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2227 19. Install the power steering pump assembly. 20. Reinstall any spark plug boot connector assembly that has stuck to a spark plug back onto the ignition coil and module assembly. 21. Locate the ignition coil and the module assembly over the spark plugs and push straight down. 22. Clean any loose lubricant that is present on the ignition coil and the module assembly to the camshaft housing bolts. 23. Apply pipe sealant GM P/N 1052080 or the equivalent onto the ignition coil and the module cover assembly to the camshaft housing bolts. Tighten the bolts to 15 Nm (11 ft. lbs.) + 30 degrees. NOTE: Do not compress the lifter plungers using a vise or other tool. This will cause more air to enter the lifter assembly and will take more time to bleed out once the lifters are installed. 24. Install the electrical connector to the ignition coil and the module assembly. 25. Connect the negative battery cable. 26. If new lifters have been installed or the lifters bled down while the engine was disassembled, excessive lifter noise may be experienced. This is a normal condition and no engine damage is occurring. Use the following procedure to purge air from the lifters: a. Start the engine and allow the engine to warm up at idle for 5 minutes. b. Increase the engine speed to 2000 RPM until the lifter noise is gone. c. Return the engine to idle for an additional 5 minutes or perform a road test. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2228 Camshaft: Service and Repair Intake - Removal ^ Tools Required J 36011 Spark Plug Connector Assembly Remover, or equivalent. NOTE: Any time the camshaft housing to the cylinder head bolts are loosened or removed, the camshaft housing to the cylinder head gasket must be replaced. During disassembly, ensure that the valve lifters are kept together and identified so that they can be reinstalled in the original locations. Before disassembling the valve mechanism, make a compression test and note the results. 1. Disconnect the negative battery cable. 2. Remove the ignition coil and the module assembly electrical connections. 3. Remove the ignition coil and the module assembly to the camshaft housing bolts. 4. Remove the assembly by pulling straight up. 5. Use the spark plug connector assembly remover in order to remove the connector assembly if stuck to the spark plugs. Use the tool by first twisting then pulling up on the connector assembly. 6. Remove the camshaft position sensor connector. 7. Remove the power steering pump and position aside. Do not disconnect the power steering lines. 8. Remove the vacuum line from the fuel pressure regulator and the fuel injector harness connector. 9. Remove the fuel line retaining clamp from the bracket on top of the intake camshaft housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2229 10. Remove the fuel rail to the camshaft housing retaining bolts. 11. Remove the fuel rail from the cylinder head as follows: ^ Cover the injector openings in the cylinder head. ^ Cover the injector nozzles. ^ Leave the fuel lines attached and the position fuel rail aside (on top of the master cylinder). 12. Disconnect, but do not remove from the vehicle, the timing chain housing at the intake camshaft housing. 13. Remove the camshaft housing cover to the camshaft housing retaining bolts. NOTE: Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts. Leave the two bolts loosely in place in order to hold the camshaft housing while separating the camshaft cover from the housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2230 14. Remove the camshaft housing to the cylinder head retaining bolts. CAUTION: Tighten the bolts evenly in order to prevent the cover from binding on the dowel pins. 15. Push the cover off the housing by threading four of the housing to head retaining bolts into the tapped holes in the camshaft housing cover. 16. Remove the two loosely installed camshaft housing to head bolts. 17. Remove the cover and discard the gaskets. 18. Loosely reinstall one camshaft housing to cylinder head bolt in order to retain the housing during the camshaft and lifter removal. 19. Note the position of the chain sprocket dowel pin for reassembly. Remove the camshaft being careful not to damage the camshaft or the journals. NOTE: The valve lifters are not serviceable. Replace faulty valve lifters. Coat the valve lifter with the Camshaft and Lifter Prelube GM P/N 12345501 or the equivalent. If the new lifters are installed, add the Engine Oil Supplement GM P/N 1052367, or the equivalent, to the engine oil. 20. Remove the valve lifters as follows: ^ Keep the lifters in order to reinstall the lifters to the original locations. ^ In order to minimize the lifter bleed down, perform the following procedure: ^ Store the lifters upside down, opposite of the installed position, on a level surface. ^ Store the lifters submerged in clean engine oil. NOTE: Ensure that the alignment dowel pins are in the cylinder head prior to installing the camshaft housing. 21. Remove the camshaft housing and the gasket. NOTE: Do not attempt to repair the camshaft, replace if damaged. If a new camshaft is installed, all of the valve lifters actuated by the camshaft must also be replaced. 22. Inspect the following camshaft components for damage: ^ The sprocket Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Exhaust - Installation > Page 2231 ^ The keyway and the threads ^ The camshaft position sensor reluctor 23. Inspect the camshaft bearing surfaces and the camshaft lobes for the following damage: ^ Wear ^ Galling ^ Gouges ^ Overheating or discoloration NOTE: If a new camshaft has been installed, add the Engine Oil Supplement GM P/N 1052367 or the equivalent to the engine oil. Coat the entire camshaft with the camshaft and lifter prelube GM P/N 12345501 or the equivalent. 24. Measure the bearing journals diameter with a micrometer. If out of specification, replace the camshaft. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Tools and Equipment > Camshaft Sprocket Timing Alignment Pins Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Tools and Equipment > Camshaft Sprocket Timing Alignment Pins > Page 2234 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Tools and Equipment > Camshaft Sprocket Timing Alignment Pins > Page 2235 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Tools and Equipment > Camshaft Sprocket Timing Alignment Pins > Page 2236 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Description and Operation Lifter / Lash Adjuster: Description and Operation Direct acting hydraulic valve lifter are used. The valve lifter body includes a hardened iron contact foot bonded to a steel shell. These lifters are not repairable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Description and Operation > Page 2240 Lifter / Lash Adjuster: Testing and Inspection A light tapping at one-half engine speed, or any varying frequency, can indicate a valve train problem. These tapping noises increase with engine speed. Before attempting to judge the valve train noises, thoroughly warm up the engine. By doing this you will bring all engine components to a normal state of expansion. Also, run the engine at various speeds and listen for engine noises with the hood closed while sitting in the driver's seat. The causes of the valve train noise include the following conditions: ^ Low oil pressure ^ Broken valve springs ^ Sticking valves ^ Lifters worn, dirty or failed ^ Worn valve guides ^ Excessive valve stem to guide clearance ^ Failed oil drain back valve Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Engine - Correction To Balance Shaft Holding Tool Balance Shaft: Technical Service Bulletins Engine - Correction To Balance Shaft Holding Tool File In Section: 6 - Engine Bulletin No.: 77-61-13 Date: August, 1997 SERVICE MANUAL UPDATE Subject: Section 6A - Engine Mechanical - Balance Shaft Holding Tool Models: 1997 Chevrolet Cavalier, Malibu 1997 Pontiac Sunfire, Grand Am 1997 Buick Skylark 1997 Oldsmobile Achieva with 2.4L Engine (VIN T - RPO LD9) In the 1997 Service Manual Section 6A or the Engine Section, the Balance Shaft Holding Tool was incorrectly specified as J 38122, on Pages 6A-131, 132, 134, and 6A-136. The correct tool number for the Balance Shaft Holding Tool is J 41088. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > General Balance Shaft: Specifications General Bore Roundness .................................................................................................................................. .......................................... 0.025 mm (0.0009 inches) Bearing Thickness .................................................................................................................................................. 1.500-1.508 mm (0.0590-0.0593 inches) Bearing I.D. ....................................................................................................................................................... 30.019-30.061 mm (1.1819-1.1835 inches) Endplay .......................................................................... ....................................................................................... 0.185-0.455 mm (0.0073-0.0179 inches) Housing Flatness Maximum ......................................................................................................................................................... 0.076 mm (0.0030 inches) Housing Bore ..................................................................................................................................................... 33.025-33.050 mm (1.3001-1.3021 inches) Journal Roundness Maximum ...................................................................................................................................................... 0.005 mm (0.0002 inches) Journal Taper ........................................................................................................................................................... 0.000-0.010 mm (0.000-0.0004 inches) Shaft Journal O.D. ............................................................................................................................................. 29.950-29.975 mm (1.1791-1.1801 inches) Shaft Groove Width ....................................................................................................................................................... 3.23-3.40 mm (0.127-0.134 inches) Thrust Plate Thickness ........................................................................................................................................... 2.945-3.045 mm (0.1159-0.1199 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > General > Page 2248 Balance Shaft: Specifications Tightening Balance Shaft: To Block Bolts (13 mm hex) ................................................................................................................ ................................................ 25 Nm (18 ft. lbs.) To Block Bolts (15 mm hex) .................................. .............................................................................................................................. 53 Nm (39 ft. lbs.) To Block Bolts (18 mm hex) ...................................................................................................................................................... 40 Nm (30 ft. lbs.) + 60° To Crankshaft .................................................................................................... ..................................................................... 175 Nm (129 ft. lbs.) + 90° To Housing Bolts (8 mm hex) ..................................................................................................................................................... 10 Nm (11 ft. lbs.) + 45° Cover Nut and Bolt .............................................................................................................................. ............................................... 13 Nm (115 inch lbs.) Housing Bolts (10 mm hex) ............................................................................................................................................................ 15 Nm (11 ft. lbs.) + 40° Thrust Plate To The Balance Shaft Housing ....................................................................................................................................... 13 Nm (115 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > Page 2249 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul Balance Shaft: Service and Repair Balance Shaft - Overhaul DISASSEMBLY 1. Remove the oil pump pick-up screen. Pry it out with a suitable tool. 2. Loosen all of the housing bolts. 3. Separate the balance shaft housings. 4. Remove the balance shaft and gear subassemblies from the housing. 5. Carefully remove the bearing halves from the housing. Do not scratch or gouge the housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2252 6. Remove the thrust plate bolts. 7. Remove the thrust plate. ASSEMBLY 1. Install the thrust plate. 2. Install the thrust plate bolts. Tighten the thrust plate bolts to 13 Nm ( 115 inch lbs. ). 3. Carefully install the bearing halves into the housing. Do not scratch or gouge the housing or the bearings. 4. Lubricate the bearings, shafts and gears with GM P/N 9985705 or equivalent. 5. Install the balance shaft and gear assemblies into the housing. 6. Ensure that the timing marks on the balance shaft gears are lined up. 7. Install the upper housing half to the lower housing half. 8. Install the housing fasteners. Tighten the fasteners to 5 Nm ( 44 inch lbs. ). 9. Tighten the fasteners to final specifications after the housing assembly has been installed on the engine. CAUTION: Do not install the oil pump pick-up screen until the housing fasteners have been tightened to final specifications. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2253 Balance Shaft: Service and Repair Balance Shaft - Removal Removal Tools Required: - J 41088 Balance Shaft, Holding Plate, or equivalent. 1. Disconnect the negative battery cable. 2. Remove the engine oil pan. 3. Remove the balance shaft chain cover nut and bolt. 4. Remove the balance shaft chain cover. 5. Loosen but do remove the balance shaft chain tensioner. 6. Remove the oil pump cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2254 7. Remove the oil pump assembly. 8. Rotate the engine crankshaft until the number one piston is at TDC. 9. Use balance shaft, holding plate to prevent the balance shafts from turning while loosening the bolt. NOTE: The balance shaft driven sprocket bolt is left-hand threaded and must be loosened by rotating it in a clockwise direction. 10. Remove the balance shaft driven sprocket bolt. NOTE: Mark the surface of the driven sprocket if it is going to be reused. This will insure that the chain continues to ride on the same tooth surface. If a new driven sprocket will be installed, either surface can be placed against the shaft. 11. Remove the driven sprocket from the shaft. 12. Remove the balance shaft assembly fasteners and remove the assembly to the bench. 13. Check the balance shaft end play prior to disassembling the balance shaft housing. ^ Set up the indicator to read off the back of the shafts. ^ Press against the one shaft and note the movement. ^ Repeat the above step on the other shaft. ^ Compare against specifications. ^ If out of specs, check the thrust plate for wear. Replace if necessary. If the end play is out of specs and the thrust plate is not worn, replace the balance shafts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2255 Balance Shaft: Service and Repair Installation Installation 1. Install the balance shaft assembly to the engine block. Use GM P/N 123454493, or equivalent on the housing to block bolts. Tighten the balance shaft assembly to the engine block bolts to specifications. 2. Install the balance shaft driven sprocket. Tighten the bolt to 30 Nm (22 ft. lbs.) + 45°. Use balance shaft, holding plate to hold balance shafts in the correct timed location. 3. Install the balance shaft chain tensioner and torque to specifications. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2256 4. Install the balance shaft chain cover. Tighten the nut and the bolt to 13 Nm ( 115 inch lbs. ). 5. Install the oil pan gasket and the oil pan. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2257 Balance Shaft: Service and Repair Timing Balance Shafts to Engine Timing Balance Shafts to Engine Tools Required: J 38122 Balance Shaft Holder J 36660 Torque Angle Meter 1. Install the balance shaft assembly to the block. Use Loctite 272 GM P/N 12345493 on the housing assembly to the block bolts. 2. If the balance shaft housing was disassembled, loosely assemble the housing assembly to the block. 3. Install the balance shaft assembly to the block. Use Loctite 272 GM P/N C12345493 on the housing assembly to the block bolts. 4. If the balance shaft housing was disassembled, loosely assemble the housing assembly to the block. 5. Tighten the housing fasteners in sequence. Tighten ^ Tighten fasteners 1, 2, 4, 5, 6 and 7 to 15 Nm ( 11 lb ft ) + 40 degrees. ^ Tighten fasteners 3 and 8 to 10 Nm ( 89 lb in ) + 40 degrees. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2258 6. Tighten the housing assembly to block bolts in sequence. Tighten ^ Tighten bolts 1,2 and 4 to 25 Nm ( 18 lb ft ) + 70 degrees. ^ Tighten bolt 3 to 40 Nm ( 30 lb in ) + 60 degrees. ^ Tighten bolt 5 to 53 Nm ( 39 lb ft ). 7. Ensure that the balance shafts spin freely. 8. If the balance shaft housing was disassembled, install the oil pump pick-Lip screen into the housing. Lightly tap it into place with a plastic hammer. Important: If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise. 9. Install the timed balance shaft and housing assembly to the engine using the following steps: 9.1. Place the number one piston at TDC. 9.2. Rotate the crankshaft 90 degrees. 9.3. Install the J 38122 on to the balance shaft assembly to ensure the shafts do not rotate while the driven sprocket bolt is tightened. Notice: A new balance shaft driven sprocket bolt must be used any time the bolt is removed. If a new bolt is not used, the balance shaft sprocket may slip allowing the balance shafts to become mistimed and cause engine vibration. Important: The surface that was marked during disassembly of the driven sprocket must show if it is going to be reused. This will insure that the chain continues to ride on the same surface. If a new driven sprocket will be installed, either surface can be placed against the shaft. 10. Install the driven sprocket to the shaft. Important: The balance shaft driven sprocket bolt is left hand threaded and must be tightened by rotating it in a counter clockwise direction. 11. Install the driven sprocket bolt. Finger tighten. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2259 12. Install the balance shaft chain guide. 13. Press the chain guide tightly against the chain. 14. Tighten the chain tensioner bolt. Tighten ^ Tighten the chain tensioner bolt to 13 Nm ( 115 lb in ). 15. Tighten the balance shaft driven sprocket bolt. Tighten ^ Tighten the driven sprocket bolt to 30 Nm ( 22 lb ft ). Use the J C36660 in order to rotate the bolt an additional 45 degrees. 16. Remove the J 38122 from the balance shaft housing assembly. 17. Loosen the balance shaft chain guide bolt. Important: A brass feeler gauge needs to be used in order to ensure correct measurements are obtained. If a steel gauge is used, it will not bend to conform to the guide and will cause incorrect measurements. 18. Adjust the balance shaft drive chain tension. Insert a 1 mm (0.040 in) brass feeler gauge between the chain guide and the chain. 19. Press the guide against the chain using about three pounds of force. 20. Install the chain tensioner bolt. Tighten ^ Tighten the chain tensioner bolt to 13 Nm ( 115 lb in ). 21. Install the balance shaft chain cover. 22. Install the balance shaft chain cover nut and bolt. Tighten ^ Tighten the chain cover nut and bolt to 13 Nm ( 115 lb in ). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Page 2260 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Bearing > Component Information > Specifications Balance Shaft Bearing: Specifications Bearing Clearance ................................................................................................................................................. 0.044-0.111 mm (0.0017-0.0044 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain > Component Information > Specifications Balance Shaft Chain: Specifications Chain Slack [1] .................................................................................................................................... .............................................. 1.0 mm (0.040 inches) Maximum Groove Depth .................................. ................................................................................................................................. 2.5 mm (0.100 inches) [1] With 6 lb Of Pressure Applied To The Guide Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement Balance Shaft Chain: Service and Repair Tensioner Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine oil pan. 3. Remove the balance shaft chain cover. 4. Remove the balance shaft chain tensioner bolt. 5. Remove the balance shaft chain tensioner. INSTALLATION PROCEDURE 1. Install the balance shaft chain tensioner. NOTE: A brass feeler gauge needs to be used in order to ensure correct measurements are obtained. If a steel gauge is used, it well not bend in order to conform to the guide and it will allow for incorrect measurements. 2. Adjust the balance shaft drive chain tension by inserting a 1 mm (0.040 inches) brass feeler gauge between the chain guide and the chain. Press the guide against the chain using about three pounds of force. 3. Tighten the chain tensioner fastener. Tighten the bolts to 13 Nm (115 inch lbs.). 4. Install the balance shaft chain cover. 5. Install the balance shaft chain cover nut and bolt. Tighten the nut and bolt to 13 Nm (115 inch lbs.). 6. Install the oil pan gasket. 7. Install the oil pan. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement > Page 2269 Balance Shaft Chain: Service and Repair Chain Replacement Removal Tools Required, or equivalent: J 38122 Harmonic Balancer Holder J 24420-B Harmonic Balance Puller NOTE: Anytime the drive chain is replaced the drive and driven sprockets also need to be replaced. 1. Disconnect the negative battery cable. 2. Remove the Engine/Transmission assembly from the vehicle. 3. Support the engine with chains and a suitable hoist. 4. Remove the starter motor. See Starting and Charging. 5. Remove the torque converter to the flex plate bolts. Hold the crankshaft balancer with the harmonic balancer holder. 6. Remove the Transmission selector cable. 7. Remove the engine torque strut bracket. 8. Remove the Transmission to the engine brace. 9. Remove the Transmission from the engine. See Transmission and Drivetrain. 10. Remove the flex plate. See Transmission and Drivetrain. 11. Clean the flex plate bolt threads and crankshaft threads with nylon bristle brush. 12. Remove the crankshaft balancer pulley. Use the harmonic balancer holder and the harmonic balance puller. 13. Attach the engine stand fixture to the engine. Install the engine on the stand. 14. Remove the ignition coil and module assembly. 15. Remove the spark plugs. See Powertrain Management. 16. Remove the engine front cover. 17. Rotate the engine to the TIMED position and remove the timing chain. See: Timing Components/Timing Chain/Service and Repair 18. Remove the timing chain housing. 19. Rotate the engine on the engine stand 180° in order to access oil pan. 20. Remove the oil pan. 21. Remove the oil pan gasket. 22. Remove the balance shaft assembly. 23. Remove the crankshaft. 24. Remove the balance shaft drive chain. Installation 1. Install the balance shaft drive chain. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement > Page 2270 2. Install the crankshaft. 3. Install the balance shaft assembly. 4. Time the balance shaft. 5. Install the oil pan gasket. 6. Install the oil pan. 7. Rotate the engine 180 degrees on the stand in order to install the timing chain housing and the other components. 8. Install the timing chain. 9. Install the timing chain housing. 10. Install the front timing chain cover. Install the upper engine mount bracket. See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair 12. Install the lower engine strut mount bracket. 13. Install the spark plugs. See Powertrain Management. 14. Install the ignition coil and module assembly. 15. Connect the engine to the chain hoist and remove the engine stand fixture from the engine block. 16. Install the crankshaft balancer pulley. 17. Install the flex plate to the engine. See Transmission and Drivetrain. 18. Connect the Transmission to the engine. See Transmission and Drivetrain. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement > Page 2271 19. Install the Transmission to the engine brace. 20. Install the Transmission to the engine brace bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 21. Install the Transmission selector cable. See Transmission and Drivetrain. 22. Install the torque converter to the flex plate bolts. 23. Install the starter motor assembly to the engine. See Starting and Charging. 24. Install the Engine/Transmission assembly. 25. Refill all fluid levels to specification. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Gear > Component Information > Specifications > General Balance Shaft Gear: Specifications General Gear Diameter ................................................................................................................................................... 61.050-61.145 mm (2.4035-2.4073 inches) Gear Backlash ....................................................................................................................................................... 0.008-0.086 mm (0.0003 0.0034 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Gear > Component Information > Specifications > General > Page 2276 Balance Shaft Gear: Specifications Tightening Balance Shaft Driven Sprocket Bolt (left hand thread) ........................................................................ ................................................................................................... 30 Nm (22 ft. lbs.) + 45° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Clearance ............................................................................................................................................ ................... 0.013-0.053 mm (0.0005-0.0020 inches) Rod Bearing Inside Diameter ............................................................................................................................. 48.013-48.028 mm (1.8903-1.8909 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Installation Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Installation NOTE: If the number one piston and the rod assembly were removed, the engine must be lifted prior to reinstallation in order to gain clearance for the torque angle meter usage. The engine does not have to be lifted to reinstall numbers two, three, and four piston and rod assemblies. Use the engine support fixture to gain this clearance. 1. Install the balance shafts. 2. Install the new oil pan gasket. 3. Install the oil pan. 4. Start the engine and inspect for leaks. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Installation > Page 2282 Connecting Rod Bearing: Service and Repair Removal Procedure Tools Required, or equivalent: J 28467-360 Engine Support Fixture J 36660 Torque Angle Meter 1. Disconnect the negative battery cable. 2. Remove the oil pan. 3. Remove the balance shafts. 4. Remove the rod bearing cap. 5. Remove the main bearing cap. 6. Inspect the bearing surfaces for wear and gouges or imbedded foreign material. NOTE: Bearing failure, other than normal wear must be investigated carefully. Inspect the crankshaft or connecting rod and the bearing bores. 7. Inspect outer surfaces for the following things: ^ Wear. Surface wear indicates either movement of the insert or high spots in the surrounding material. ^ Overheating. ^ Looseness or rotation. 8. Inspect the thrust surfaces for the following things: NOTE: Method A yields measurements from which the bearing clearance can be computed. Method B yields the bearing clearance directly. Method B does not give any indication of bearing journal runout. CAUTION: Do not mix the inserts of different nominal size. ^ Wear. ^ Grooving. Grooves are caused by irregularities of the crankshaft thrust surface. 9. Remove the bearing cap bolts. If the bolts are stretched replace them. 10. Measure the bearing clearance. To determine the correct replacement insert size, the bearing clearance must be measured accurately. Either of the following two methods may be used, however, method A gives more reliable results and is preferred. Method A 1. Measure the crankshaft journal diameter with a micrometer in several places, approximately 90 degrees apart, and average the measurements. 2. Measure the taper and runout. 3. Measure the bearing insert I.D. with an inside micrometer. Measure at 90 degrees to the split line of the bearing. Method B 1. Clean and install the bearing inserts, and the crankshaft into the block. 2. Place a piece of gaging plastic across the entire bearing width. 3. If the main bearing clearance is being measured, support the crankshaft away from the gaging plastic so total clearance is being measured. 4. Seat the bearing cap carefully by tapping it lightly with a suitable tool. CAUTION: To prevent the possibility of cylinder block and/or main bearing cap damage, tap the main bearing caps into the cylinder block cavity with a brass or leather mallet before installing the attaching bolts. Do not use the attaching bolts to pull the caps into their seats. 5. Tighten the bearing cap bolts to specification. NOTE: Do not rotate the crankshaft. 6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Installation > Page 2283 bearing cap. 7. Measure the flattened gaging plastic package. 8. Remove all traces of the gaging plastic after measuring. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Dimensions Connecting Rod: Specifications Connecting Rod Dimensions Connecting Rod: I.D. at the Small End ...................................................................................................................................... 22.007-22.027 mm (0.8664-0.8642 inches) I.D. at the Large End ...................................................................................................................................... 51.167-51.193 mm (2.0144-2.0154 inches) Width at the Small End .................................................................................................................................. 23.170-23.220 mm (0.9122-0.9142 inches) Width at the Large End .................................................................................................................................. 23.170-23.220 mm (0.9122-0.9142 inches) Weight, in the Same Engine, All Within ................................................................................................................................................... 2 g (0.0705 oz) Clearance to Piston Pin ..................................................................................................................................... 0.007-0.031 mm (0.00027-00122 inches) Center to Center Distance ........................................................................................................................ 142.450-142.550 mm (5.6125-5.6164 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Dimensions > Page 2288 Connecting Rod: Specifications Connecting Rod Nut Connecting Rod Nuts ............................................................................................................................................................. 25 Nm + 80° (18 ft. lbs) + 80° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2289 Connecting Rod: Description and Operation The connecting rods are forged steel, heat treated and shot peeped. The connecting rod incorporates the floating piston pin. An oil cooling hole, which indexes once per revolution with the connecting rod oil feed hole, is drilled in the large end of the rod for piston cooling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Gear/Hub Torque Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Gear/Hub Torque Specifications Balancer to the Crankshaft .......................................................................................................................................................... 175 Nm (129 ft. lbs.) + 90° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Gear/Hub Torque Specifications > Page 2294 Crankshaft Gear/Sprocket: Specifications Crankshaft Pully/Hub Torque Specification Crankshaft Balancer to the Crankshaft ............................................................................................................................................ 175 Nm (129 lb ft) +90° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation Crankshaft Gear/Sprocket: Service and Repair Installation CAUTION: Failure to follow this procedure could result in severe engine damage. 1. Install the intake camshaft sprocket onto the camshaft with the marked surface showing. 2. Install the intake camshaft sprocket Retaining bolt and washer. Tighten the bolt to 70 Nm (52 ft. lbs.) while holding the sprocket with the camshaft sprocket wrench. 3. Use Adhesive/Sealant Compound GM P/N 12345493 or equivalent on the camshaft sprocket bolt. 4. Install the camshaft sprocket timing alignment pin through the holes in the camshaft sprockets into the holes in the timing chain housing in order to position the camshaft for correct timing. 5. If the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins, use the following procedure: a. The crankshaft must be rotated 90 degrees clockwise off of the TDC in order to give the valves adequate clearance to open. b. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to the top dead center. WARNING: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. NOTE: The side of the timing chain that was marked during removal must be showing when the chain is installed. 6. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2297 7. Set the camshaft sprockets at the timed position and use the following procedure in order to install the timing chain: a. Remove the alignment dowel pin from the intake camshaft. b. Use the camshaft sprocket wrench in order to rotate the intake camshaft sprocket counter clockwise enough to slide the timing chain over the intake camshaft sprocket. c. Release the camshaft sprocket wrench. The length of the chain between the two camshaft sprockets will tighten. d. If properly timed the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 8. Leave the alignment dowel pins installed. 9. Raise and support the vehicle. 10. With the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and the recheck marks. 11. In order to reload the timing chain tensioner assembly to its zero position, form a keeper from a piece of heavy gauge wire. 12. Apply a slight force on the tensioner blade in order to compress the plunger. 13. Insert a small screwdriver into the reset access hole, and pry the ratchet pawl away from the ratchet teeth while forcing the plunger completely in the hole. 14. Install the keeper between the access hole and the blade. 15. Install the tensioner assembly to the chain housing. Recheck the plunger assembly installation, it is correctly installed when the long end is toward the crankshaft. 16. Install the timing chain tensioner bolts. Tighten the bolts to 10 Nm (89 inch lbs.). 17. Lower the vehicle enough to reach and remove the alignment dowel pins. 18. Rotate the crankshaft clockwise (normal rotation) two full rotations. 19. Align the crankshaft keyway with the mark on the cylinder block and reinstall alignment dowel pins. 20. Alignment dowel pins will slide in easily if the engine is timed correctly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2298 21. Install the timing chain guides. 22. Install the engine front cover. 23. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2299 Crankshaft Gear/Sprocket: Service and Repair Removal ^ Tools Required, or equivalent: J 36800 Camshaft Sprocket Timing Alignment Pin J 39579 Camshaft Sprocket Wrench NOTE: Before removing the timing chain, read the entire procedure. The timing chain and the crankshaft sprocket must be marked in order to insure reassembly with the same side facing out at the time of reassembly. CAUTION: The timing chain is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. 1. Disconnect the negative battery cable. 2. Remove the engine front cover. 3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes line up with the holes in the timing chain housing. 4. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the "Timed" position. 5. Remove the timing chain guides. 6. Raise and support the vehicle. 7. Ensure that all of the slack in the timing chain is above the tensioner assembly. 8. Remove the timing chain tensioner. 9. The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward. CAUTION: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur. 10. If difficulty is encountered in removing the timing chain tensioner shoe, use the following procedure in order to remove the intake camshaft sprocket. a. Lower the vehicle. b. Hold the intake camshaft sprocket with the camshaft sprocket wrench and remove the sprocket bolt and washer. c. Remove the washer from the bolt and rethread the bolt back into the camshaft by hand (the bolt provides a surface to push against). d. Remove the intake camshaft sprocket. Use a three-jaw puller in the three relief holes in the sprocket. 11. Remove the tensioner assembly retaining bolts and tensioner. CAUTION: The timing chain and the crankshaft sprocket must be marked prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2300 12. Mark the crankshaft sprocket and the timing chain outer surface. 13. Remove the timing chain. 14. Clean the old sealant off of the bolt with a wire brush. 15. Clean the threaded hole in the camshaft with a round nylon bristle brush. 16. Inspect the parts for wear and replace the parts as necessary. Some scoring of the timing chain shoe and the guides is normal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Main Bearing Dimension/Clearance Specifications Crankshaft Main Bearing: Specifications Main Bearing Dimension/Clearance Specifications Main Bearing Clearance ............................................................................................................................................... 0.013-0.073 mm (0.0005-0.0030 in) Main Bearing Inside Diameter .................................................................................................................................. 60.033-60.071 mm (2.3635-2.3650 in) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Main Bearing Dimension/Clearance Specifications > Page 2305 Crankshaft Main Bearing: Specifications Main Bearing Cap Torque Crankshaft Bearing Cap Bolts ............................................................................................................................................... 20 Nm + 90° (15 ft. lbs.) + 90° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Bearing Journal Main Bearing Journal Diameter ..................................................................................................................... 60.031-60.010 mm (2.3634-2.3626 inches) Width [1] ....................................................................................................................................................... 27.837-27.913 mm (1.0959-1.0989 inches) Out of Round Maximum ........................................................................................................................................................... 0.005 mm (0.0002 inches) Straightness Taper ................................................................................... ................................................................................. 0.007 mm (0.0003 inches) Crank shaft End Play ......................................................................................................................................... 0.087-0.243 mm (0.0034-0.0095 inches) Runout [2] ........................................................................... ........................................................................................................ 0.03 mm (0.001 inches) Runout [3] ......................................................................................................................................................... ..................... 0.025 mm (0.00098 inches) Flywheel Fit .............................................................................................................................................. 0.000-0.013 mm loose (0.0000-0.0005 inches) Flange Runout Maximum ......................................................................................................................................................... 0.03 mm (0.00120 inches) Stroke of Crank ......................................................................................... ........................................................................................ 94 mm (3.70 inches) Runout of Seal Surface ......................................................................................................................................................... 0.05 mm max (0.002 inches) Rod Bearing Journal Rod Bearing Journal Diameter ......................................................................................................................... 47.975-48.00 mm (1.8887-1.8897 inches) Rod Bearing Inside Diameter ......................................................................................................................... 48.013-48.028 mm (1.8903-1.8909 inches) Out of Round ................................................................................................. ........................................................................... 0.005 mm (0.0002 inches) Straightness, Taper ...... ............................................................................................................................................................. 0.005 mm (0.0002 inches) Clearance ........................................................................................................................................................... 0.013-0.053 mm (0.0005-0.0020 inches) Rod Side Clearance ............................................................................................................................................ 0.150-0.450 mm (0.0059-0.0177 inches) [1] Main Thrust Bearing Journal No. 3, Including Fillets [2] Crankshaft at the Flywheel Flange Maximum. [3] Crankshaft Maximum. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2309 Crankshaft: Description and Operation The crankshaft is cast nodular iron with eight counterweights. The number five counterweight is also the ignition system reluctor wheel. The main bearing journals are cross-drilled, except #5, and the upper bearings are grooved. The crankshaft has a pressed-on balance shaft drove sprocket. Number three main bearing is the thrust bearing. A harmonic balancer is used to control torsional vibration. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Electrical Specifications Engine Block Heater: Electrical Specifications Engine Coolant Heater Volts A.C......................................................................................................... ..............................................................................120 Wattage........................................................... .............................................................................................................................................................. ......400 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Electrical Specifications > Page 2314 Engine Block Heater: Mechanical Specifications Engine Coolant Heater to coolant pump - 2.4L (VIN T)..............................................................................................................................15 N.m (11 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service Precautions > Technician Safety Information Engine Block Heater: Technician Safety Information CAUTION: ^ This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to Service Precautions / Air Bags (Supplemental Restraint Systems) before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service Precautions > Technician Safety Information > Page 2317 Engine Block Heater: Vehicle Damage Warnings Fastener Requirements NOTE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Exposed Electrical Terminals CAUTION: When removing or Installing any electrical unit or when a tool or equipment could easily come In contact with a "LIVE" exposed electrical terminal, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless otherwise instructed, the Ignition switch must be In the "OFF" or "LOCK" position. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service Precautions > Page 2318 Engine Block Heater: Description and Operation The optional engine coolant heater is used to preheat engine coolant for cold weather starting. The heating element is installed into the water jacket of the engine block for the 2.2L (VIN 4) or in the coolant pump housing for the 2.4L (VIN T). The unit has a detachable electrical cord. If the heater fails to operate, check cord, connections and power supply before replacing the heating element. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service Precautions > Page 2319 Engine Block Heater: Testing and Inspection If the engine coolant heater fails to heat the coolant, check all electrical connections before proceeding. 1. Check for 110 volt AC external power source. 2. Check continuity and shorts to ground of engine block heater cord. Replace cord as required. 3. The heating element should indicate continuity with an ohm meter. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Coolant Heater Engine Block Heater: Service and Repair Engine Coolant Heater Engine Coolant Heater And Radiator Outlet Pipe Assembly Engine Coolant Heater Cord Routing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Coolant Heater > Page 2322 REMOVE OR DISCONNECT 1. Drain coolant. 2. Raise vehicle. 3. Cord from engine coolant heater. 4. Engine coolant heater. IF NOT ORIGINALLY EQUIPPED WITH AN ENGINE COOLANT HEATER: 1. Remove threaded plug from coolant pump housing. INSTALL OR CONNECT 1. Engine coolant heater. TIGHTEN ^ Engine coolant heater to 15 N.m (11 lb. ft.). 2. Heater cord to the block heater. IMPORTANT ^ Cord must not contact hot surfaces or any moving parts. 3. Lower vehicle. 4. Fill coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Coolant Heater > Page 2323 Engine Block Heater: Service and Repair Heater Cord Replacement REMOVE OR DISCONNECT 1. Negative battery cable. 2. Cord from engine coolant heater. 3. Cord assembly. Cord Routing And Engine Coolant Heater Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Coolant Heater > Page 2324 Engine Coolant Heater Cord Routing INSTALL OR CONNECT 1. Cord assembly. IMPORTANT ^ Cord must not contact hot surfaces or any moving parts. 2. Cord to engine coolant heater. 3. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Balancer to the Crankshaft .......................................................................................................................................................... 175 Nm (129 ft. lbs.) + 90° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2328 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL PROCEDURE ^ Tools Required, or equivalent: J 38122 Crankshaft Balancer Holder J 24420-B Crankshaft Balancer Puller 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt. 3. Raise and suitably support the vehicle. 4. Remove the right splash shield. 5. Remove the balancer retaining bolt and the washer using crankshaft balancer holder to prevent crankshaft rotation when loosening the bolt. 6. Remove the balancer assembly using crankshaft balancer puller. INSTALLATION PROCEDURE 1. Lubricate the front seal and the sealing surface of the balancer with chassis grease GM P/N 1051344 or equivalent. NOTE: The automatic transmission crankshaft balancer must not be installed on a manual transmission equipped engine. 2. Install the balancer onto the crankshaft indexing keyway. Tap into place using a rubber or sand-filled mallet. CAUTION: Do not use the torque angle meter to rotate the retaining bolt an additional 90 degrees. The torque capacity of the tool will be exceeded and damage to the tool will result. 3. Install the retaining bolt and the washer. Tighten the bolt to 175 Nm (129 ft. lbs.) while using crankshaft balancer holder to prevent crankshaft rotation. Put a mark on the socket next to one of the four marks on crankshaft balancer holder. This mark will represent the 0 degree point. Tighten the bolt by rotating the socket clockwise 90 degrees. At 90 degrees the socket will index with the next mark on the tool. 4. Install the right splash shield. 5. Lower the vehicle. 6. Install the accessory drive belt. 7. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2329 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Clearance in the Bore .................................................................................................................................................... 0.010-0.042 mm (0.0006-0.0018 in) Compression Height .......................................................................................................................................................... 29.27-30.03 mm (1.180-1.182 in) Piston Diameter @70° F (21° C) .............................................................................................................................. 89.968-89.984 mm (3.5420-3.5247 in) Piston Pin Bore ID @ 70° (21°) ................................................................................................................................ 22.022-22.006 mm (0.8662-0.8664 in) Weight Less Pin and Rings ...................................................................................................................................... 345 g +/- 6 g (12.075 oz +/- 0.1764 oz) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2333 Piston: Description and Operation The pistons are cast aluminum. The piston rings are of a low tension type to reduce friction. The top compression ring is ductile iron with a molybdenum facing and phosphate coated sides. The second compression ring is gray iron. The oil ring is a 3-piece spring construction with chromium plating. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2334 Piston: Service and Repair WARNING: Bodily injury may occur if carburetor cleaning fluid is exposed to the skin or if the fumes are inhaled. CAUTION: It is essential that the piston ring grooves are cleaned of carbon to the bare metal. Do not scrape the piston skirt. 1. Clean the following contaminates from the piston, the piston pin and connecting rod: ^ Sludge ^ Carbon 2. Clean the varnish from the piston pin by soaking it in Parts Immersion Solvent GM P/N 12345368 or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin <--> [Piston Pin, Engine] > Component Information > Specifications Piston Pin: Specifications Clearance in the Bore ............................................................................................................................................. 0.010-0.042 mm (0.0006-0.0018 inches) Pin to Piston Clearance ...................................................................................................................................... 0.002-0.011 mm (0.00007-0.00043 inches) Pin to Rod Clearance ........................................................................................................................................... 0.007-0.032 mm (0.00027-0.0013 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin <--> [Piston Pin, Engine] > Component Information > Specifications > Page 2338 Piston Pin: Service and Repair WARNING: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury. 1. Disassemble the piston rings. Use a suitable tool in order to expand the rings. The piston rings must not be reused. NOTE: Two retainers hold the piston pins in place. No special tools are required to remove or, install the retainers or the piston pins. If the retainers are not damaged, reuse the retainers. Ensure that the piston pin is not damaged. 2. Disassemble the piston pin retaining clips. 3. Disassemble the piston pin. NOTE: Install the piston onto the connecting rod in either direction. 4. Assemble the connecting rod and the piston. CAUTION: Install the piston pin retainers correctly in the retaining groove during assembly in order to avoid engine damage. 5. Use the following procedure in order to assemble the piston pin and the retainer: a. Coat the piston pin with oil. b. Install one side of one piston pin retainer into the retaining groove. Rotate the retainer until it is fully seated in the groove. c. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. d. Install the second piston pin retainer. e. Ensure that the piston moves freely. CAUTION: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin <--> [Piston Pin, Engine] > Component Information > Specifications > Page 2339 6. Install the following components of the oil control ring assembly (bottom ring): a. The expander. b. The lower oil control ring. c. The upper control ring. 7. Install the lower compression ring (second ring). Place the manufacturer's mark facing up. 8. Install the upper compression ring (top ring). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Compression Ring Width, Both ............................................................................................................................ 1.170-1.190 mm (0.0461-0.0469 inches) Compression Ring Gap: Top ...................................................................................................................................................... ...................... 0.15-0.30 mm (0.006-0.012 inches) 2nd Ring .............................................................. .................................................................................................. 0.30-0.41 mm (0.0119-0.0161 inches) Oil Rails ............................................................................................................................................... ................... 0.025-0.65 mm (0.0098-0.0256 inches) Compression Ring Side Clearance in the Groove: Top Ring ........................................................................................................................................................... 0.040-0.080 mm (0.0016-0.0031 inches) Second Ring ...................................................................................................................................................... 0.030-0.070 mm (0.0012-0.0028 inches) Oil Ring Width .................................................................................................................................................. 0.497-0.523 mm (0.01957-0.02060 inches) Oil Ring Gap ........................................................................................................................................................... 0.399-1.40 mm (0.0157-0.0551 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2343 Piston Ring: Service and Repair WARNING: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury. 1. Disassemble the piston rings. Use a suitable tool in order to expand the rings. The piston rings must not be reused. NOTE: Two retainers hold the piston pins in place. No special tools are required to remove or, install the retainers or the piston pins. If the retainers are not damaged, reuse the retainers. Ensure that the piston pin is not damaged. 2. Disassemble the piston pin retaining clips. 3. Disassemble the 'piston pin. NOTE: Install the piston onto the connecting rod in either direction. 4. Assemble the connecting rod and the piston. CAUTION: Install the piston pin retainers correctly in the retaining groove during assembly in order to avoid engine damage. 5. Use the following procedure in order to assemble the piston pin and the retainer: a. Coat the piston pin with oil. b. Install one side of one piston pin retainer into the retaining groove. Rotate the retainer until it is fully seated in the groove. c. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. d. Install the second piston pin retainer. e. Ensure that the piston moves freely. CAUTION: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2344 6. Install the following components of the oil control ring assembly (bottom ring): a. The expander. b. The lower oil control ring. c. The upper control ring. 7. Install the lower compression ring (second ring). Place the manufacturer's mark facing up. 8. Install the upper compression ring (top ring). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2345 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Intake Valve Cold Valve Lash ................................................................................................................................... 0.13 - 0.17 mm (0.005 - 0.007 inches) Exhaust Valve Cold Valve Leash .............................................................................................................................. 0.13 - 0.17 mm (0.005 - 0.007 inches) Intake Valve Hot Valve Leash ................................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Exhaust Valve Hot Valve Leash ............................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts > Component Information > Technical Service Bulletins > Engine - Installation & Torqueing of Cylinder Head Bolts Cylinder Head Bolts: Technical Service Bulletins Engine - Installation & Torqueing of Cylinder Head Bolts File In Section: 6 Engine Bulletin No.: 73-61-11 Date: June, 1997 SERVICE MANUAL UPDATE Subject: Section 6A - Revised Procedure for Installation and Torquing of Cylinder Head Bolts Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire with 2.4L Engine (VIN T - RPO LD9) This bulletin is being issued to revise the service procedure for installation and torquing of the cylinder head bolts in Section 6A of the Service Manual. The Service Manual incorrectly states the torque angle procedure used to tighten the cylinder head bolts. The installation procedure should read as follows: ^ Install the cylinder head gasket to the block. Important: Do not use any sealing material. ^ Install the cylinder head. ^ Lightly apply clean engine oil to the threads and the bottom side of the flange of the head bolt and allow the oil to drain before installing. ^ Install and tighten the cylinder head bolts in sequence. ^ Tighten Tighten bolts 1-8 to 65 N.m (40 lb ft). Tighten bolts 9 and 10 to 40 N.m (30 lb ft). ^ Then turn all bolts an additional 90° in sequence (this replaces Step 6 in the Service Manual). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Tools and Equipment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Pressure Load: Closed [1] ............................................................................................................................................ ......................................... 223-247 N (50-55 lbs.) Open [2] ................................................................ ................................................................................................................... 544-596 N (122-133 lbs.) [1] at 36.5 mm (1.4370). [2] at 26.98 mm (1.0622 inches). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Tools and Equipment > Valve Spring Depressor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Tools and Equipment > Valve Spring Depressor > Page 2365 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Installed Height, All ................................................................................................................................... 24.86-25.62 mm (0.9787-1.0024 inches) Valve Tip Above Spring Retainer, All .................................................................................................................. 0.602-0.820 mm (0.0237-0.0323 inches) Intake Valves, Valve Face Angle ................................................................... ...................................................................................................... 46 degrees Valve Seat Angle ....... .............................................................................................................................................................. ............................ 45 degrees Head Diameter .................................................................................................................................................... 35.5 ± 0.03 mm (1.3987 ± 0.0011 inches) Stem Diameter ....................................................................................................................................................... 5.921 5.941 mm (0.2331-0.2339 inches) Overall Length .................................................................... ..................................................................................................... 107.290 mm (4.2272 inches) Stem To Guide Clearance ..................................................................................................................................... 0.025-0.069 mm (0.0009-0.0025 inches) Valve Seat Width ...................................................................................................................................................... 0.94-1.90 mm (0.0370-0.0748 inches) Valve Seat Margin Minimum ........................................................................................................................................................ 0.25 mm (0.0098 inches) Valve Face Runout ..................................................................................... ................................................................................. 0.038 mm (0.0015 inches) Valve Tip to the Groove Centerline ............................................................................................................................................ 3.420 mm (0.1346 inches) Exhaust Valves, Valve Face Angle ............................................................................ ....................................................................................... 45.5 degrees Valve Seat Angle ................... .............................................................................................................................................................. ................ 45 degrees Head Diameter .................................................................................................................................................. 28.870-29.130 mm (1.1366-1.1469 inches) Stem Diameter ...................................................................................................................................................... 5.908-5.928 mm (0.2326-0.2334 inches) Overall Length .................................................................... ....................................................................................................... 108.17 mm (4.2586 inches) Stem to Guide Clearance ...................................................................................................................................... 0.038-0.082 mm (0.0016-0.0032 inches) Valve Seat Width .................................................................................................................................................... 0.094-1.90 mm (0.0037-0.0748 inches) Valve Seat Margin Minimum ........................................................................................................................................................ 0.25 mm (0.0098 inches) Valve Face Runout ..................................................................................... ................................................................................. 0.038 mm (0.0015 inches) Valve Tip to Groove Centerline ................................................................................................................................................... 3.420 mm (0.1346 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 2369 Valve: Description and Operation There are two intake and two exhaust valves per cylinder. The valve springs are conical-shaped to fit inside the valve lifter body. Rotators are used on all of the intake valves. The rotators are located at the bottom of the valve spring to reduce valve train reciprocating mass. Positive valve stem seals are used on all valves. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2375 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2376 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2377 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement Drive Belt: Service and Repair Accessory Drive Belt Replacement Drive Belt Replacement Tools Required J 37059 Accessory Drive Belt Tensioner Wrench. Caution: To avoid personal injury when rotating the accessory drive belt tensioner, use a tight fitting 13 mm wrench that is at least 46 cm (18 in) long. Use J 37059 in order to remove the accessory drive belt by rotating the tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Accessory Drive Belt Replacement > Page 2380 Drive Belt: Service and Repair Pump Drive Belt SERPENTINE BELT These vehicles have the power steering pump driven by a serpentine belt. The serpentine belt is self adjusting within tensioner operating limits. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Tensioner To Tensioner Bracket Nut ...................................................................................................................................................... 54 Nm (40 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2384 Drive Belt Tensioner: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt. 3. Remove the generator assembly. 4. Raise and support the vehicle. 5. Remove the oil filter. 6. Remove accessory drive belt idler pulley. 6.1. The A/C compressor mounting bolt. 6.2. The A/C compressor. Position it aside. 7. Remove the tensioner. Installation Procedure 1. Install the tensioner. Tighten Tighten the tensioner nut to 50 Nm (37 lb ft). 2. Install accessory drive belt idler pulley. 2.1. The A/C compressor. 2.2 The A/C compressor mounting bolts. Tighten Tighten the bolts to 54 Nm (40 lb ft). 3. Install the oil filter. 4. Lower the vehicle. 5. Install the generator assembly. 6. Install the drive belt. 7. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Mount Strut <--> [Engine Torque Strut] > Component Information > Service and Repair > Strut Bracket Engine Mount Strut: Service and Repair Strut Bracket REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the engine mount strut. 4. Remove the engine mount strut bracket bolts. 5. Remove the engine mount strut bracket. INSTALLATION PROCEDURE 1. Install the engine mount strut bracket. 2. Install the engine mount strut bracket bolts. a. Tighten the bolts on the front of the engine to 66 Nm (49 ft. lbs.). b. Tighten the bolts on the bottom of the engine to 130 Nm (96 ft. lbs.). 3. Install the engine mount strut. 4. Lower the vehicle. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Engine Mount Strut <--> [Engine Torque Strut] > Component Information > Service and Repair > Strut Bracket > Page 2390 Engine Mount Strut: Service and Repair Strut Replacement REMOVAL PROCEDURE 1. Remove the negative battery cable. 2. Raise and support the vehicle. 3. Remove the right splash shield. 4. Remove the engine mount strut bolts. 5. Remove the engine mount strut. INSTALLATION PROCEDURE 1. Install the engine mount strut and the bolts. Tighten the bolts to 100 Nm (74 ft. lbs.) + 90 degrees. 2. Install the right splash shield. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt. 3. Remove the idler pulley bracket and bolts. 4. Remove the idler pulley. INSTALLATION PROCEDURE 1. Install the idler pulley. 2. Install the idler pulley bracket and bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the drive belt. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Engine Oil Pressure: Customer Interest Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 2403 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Engine Oil Pressure: All Technical Service Bulletins Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 2409 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Technical Service Bulletins > Page 2410 Engine Oil Pressure: Specifications Oil Pressure at 3000 RPM ................................................................................................................... .............................................. 207 kPa (30 psi. min.) Oil Pressure at 900 RPM .................................. ................................................................................................................................... 69 kPa (10 psi. min.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Dipstick Tube Bolt/Screw ............................................................................................................... .................................................. 8 Nm (71 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug ............................................................................................................................... .................................................... 26 Nm (19 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2421 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2422 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity Without Filter Change ....................................................................................................................................................... 3 3/4 Liters (4 qts.) When Changing the Oil Filter, Up to an Additional 0.946 Liter or One Quart of Oil May Be Needed. Filter Type or Equivalent Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2425 Engine Oil: Fluid Type Specifications Below 60°F (16°C) ............................................................................................................................... ............................................................. SAE 5W-30 Above 0°F (-18°C) ............................................. ........................................................................................................................... SAE 10W-30 (Preferred) Engine oil with the American Petroleum Institute Certified For Gasoline Engine "Starburst" symbol of the proper viscosity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2426 Engine Oil: Description and Operation APPLICATION Oil is applied under pressure to the crankshaft, connecting rods, balance shaft assembly, camshaft bearing surfaces, valve lifters and timing chain hydraulic tensioner. All other moving parts are lubricated by gravity flow or splash. FLOW PROCESS Oil enters the gerotor type oil pump (7) thorough a fixed inlet screen. The oil pump is driven by one of the balance shafts. The oil pump body and the cover are cast aluminum, and the gerotor gears are steel. The pressurized oil from the pump passes through the oil filter (9). The oil filter is located on the left (front) side of the engine block. A by-pass valve (8) in the engine block allows continuous oil flow in case the oil filter should become restricted. Oil then enters the gallery where it is distributed to the balance shafts, the crankshaft (6), the timing chain hydraulic tensioner (10), the lifters (4) and the camshafts (1). FLOW PASSAGES The connecting rod bearings are oiled by constant oil flow passages through the crankshaft connecting the main journals to the rod journals. A groove around each main bearing furnishes oil to the drilled crankshaft passages. An oil cooling hole, which indexes once each revolution with the connecting rod oil feed hole, is drilled in the connecting bearing surface. The pressurized oil passages through the oil flow check valve (11) into the cylinder head (5) and then into each camshaft housing (2). Cast passages feed each valve lifter (4) and drilled passages feed each camshaft baring surface. An engine oil pressure switch or sensor (3) is installed at the end of the intake camshaft housing oil gallery. Oil returns to the oil pan through passages cast into the camshaft housings and the cylinder head. The timing chain housing drains directly into the oil pan. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss Engine Oil: Testing and Inspection Excessive Oil Loss An engine that has excessive oil consumption uses 1.9L (2 qts) of oil, or more, within 2,000 miles (3200 km). The following conditions are indications of excessive on consumption: a. Improperly read oil level indicator (dipstick) ^ Check the oil while the car is standing on a level surface. ^ Allow adequate drain-down time. b. Improper oil viscosity ^ Use the recommended-SAE viscosity for prevailing temperatures. c. Continuous high-speed driving d. Severe hauling, such as a trailer, causing decreased oil mileage. e. Malfunctioning crankcase ventilation system f. External oil leaks ^ Tighten the bolts, as necessary. ^ Replace the gaskets and seals, as necessary. g. Worn or omitted valve guides and/or valve stem seals ^ Replace the valve stem seals. ^ If the valve guides are wore, replace the cylinder head. h. Broken, improperly installed worn or unseated piston rings. i. Piston improperly installed or improperly fitted. j. Plugged cylinder head gasket oil drain holes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss > Page 2429 Engine Oil: Testing and Inspection Low or No Oil Pressure ^ Low oil level. Fill to full mark on oil level indicator. ^ Incorrect or malfunctioning oil pressure switch. ^ Incorrect or malfunctioning oil pressure gauge. ^ Improper oil viscosity for the expected temperature. ^ Oil pump worn or dirty. ^ Malfunctioning oil pump pressure regulator valve. ^ Plugged oil filter. ^ Oil pump screen loose plugged, or damaged. ^ Excessive bearing clearance. Replace as necessary. ^ Cracked, porous or restricted oil galleries. Repair or replace block. ^ Oil gallery plugs missing or incorrectly installed. Install plugs or repair as necessary. ^ Oil diluted by moisture or unburned fuel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss > Page 2430 Engine Oil: Testing and Inspection Oil Consumption Diagnosis ^ Excessive oil consumption (not due to leaks) is the use of 1.9L (2 qts) or more of engine oil within 2,O00 miles (3200 kilometers). The causes of excessive oil consumption include the following conditions: ^ External oil leaks. Tighten bolts and/or replace gaskets and oil seals as necessary. ^ Incorrect oil level or improper reading of oil level indicator. With the vehicle on a level surface, allow adequate drain down time and check for the correct oil level. ^ Improper oil viscosity. Use recommended SAE viscosity for the prevailing temperatures. ^ Continuous high speed driving and/or severe usage. ^ Crankcase ventilation system restrictions or malfunctioning components. ^ Valve guides and/or valve stem oil seals worn, or the seal omitted. Ream guides and install oversize service valves and/or new valve stem oil seals. ^ Piston rings broken, improperly installed, worn, or not seated properly. Allow adequate time for rings to seat. Replace broken or worn rings as necessary. ^ Piston improperly installed or miss-fitted. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Excessive Oil Loss > Page 2431 Engine Oil: Testing and Inspection Oil Leak Diagnosis Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. Use The Following Steps In Order To Find The Leak: 1. Identify the fluid, determine whether it is engine oil, automatic transmission fluid or power steering fluid. 2. At what point is the fluid leaking from? After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. After a few minutes, you should be able to find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent. Clean the area well, then dry the area. Operate the vehicle for several miles at normal operating temperature and varying speeds. After operating the vehicle, visually check the suspected component. If you still cannot locate the leak, try using the powder or black light and dye method. Perform The Following Steps In Order To Perform The Powder Method: 1. Clean the suspected area. 2. Apply an aerosol-type powder (such as foot powder) to the suspected area. 3. Operate the vehicle under normal operating conditions. 4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source. Perform The Following Steps In Order To Use The Black Light And Dye Method: 1. Pour specified amount of dye into the leaking component. 2. Operate the vehicle under normal operating conditions as directed by the tool manufacturer 3. Direct the light toward the suspect area. The dyed fluid will appear as a yellow path leading to the source. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Testing and Inspection > Page 2432 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Connector to the Block ............................................................................................................................................................ 29 Nm (21 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation The Check Oil Indicator is controlled by the IPC as commanded by the PCM via serial data. The oil level is monitored by the PCM with an Oil Level Switch. When the PCM determines a low oil condition, it commands the indicator "ON". As a bulb check procedure, the PCM will command this telltale "ON" when the IPC and PCM are powered up (ignition m OFF/UNLOCK," "RUN," or "CRANK" position) and the engine is not running. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Tighten the oil pan bolts. ^ (1) (M8 X 1.25 X 80) 24 Nm (18 ft. lbs.) ^ (2) (M8 X 1.25 X 22) 24 Nm (18 ft. lbs.) ^ (3) (M6 X 1.00 X 2.5) 12 Nm (106 inch lbs.) ^ (4) 26 Nm (19 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2446 Oil Pan: Description and Operation The oil pan is die cast aluminum. The oil pan includes an attachment to the transmission to provide additional structural support. The balance shaft assembly acts like an oil baffle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal Oil Pan: Service and Repair Removal 1. Disconnect the negative battery cable. 2. Drain the engine oil. 3. Drain and recover the coolant. See Cooling System. 4. Remove the flex plate housing. 5. Remove the right front wheel and tire assembly. 6. Remove the right splash shield. 7. Remove the drive belt. 8. Remove the A/C compressor lower bolts. See Heating and Air Conditioning. 9. Remove the transmission to the engine brace. 10. Remove the engine mount strut bracket. 11. Remove the radiator outlet pipe bolts. . 12. Remove the radiator outlet pipes from the oil pan. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2449 13. Remove the exhaust manifold brace. 14. Remove the oil pan to the flex plate cover bolt and nut. 15. Remove the flex plate cover stud for clearance. 16. Remove the radiator outlet pipe from the lower radiator hose and oil pan. 17. Remove the oil level sensor connector. 18. Remove the oil pan bolts. 19. Remove the oil pan. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2450 Oil Pan: Service and Repair Oil Pan Installation 1. Install the oil pan 2. Place the spacer in its approximate installed location but allow clearance to tighten the pan bolt directly above the spacer. 3. Tighten the oil pan bolts. ^ (1) (M8 X 1.25 X 80) 24 Nm (18 ft. lbs.). ^ (2) (M8 X 1.25 X 22) 24 Nm (18 ft. lbs.). ^ (3) (M6 X 1.00 X 2.5) 12 Nm (106 inch lbs.). ^ (4) 26 Nm (19 ft. lbs.). 4. Position the spacer into its proper location and install the stud. 5. Install the oil pan to the transmission nut. 6. Install the oil level sensor connector. 7. Install the radiator outlet pipe to the lower radiator hose and oil pan. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2451 8. Install the exhaust manifold brace. 9. Install the radiator outlet pipes to the oil pan. 10. Install the radiator outlet pipe bolts. See Cooling System. 11. Install the engine mount strut bracket. 12. Install the transmission to the engine brace. Tighten the bolts to 50 Nm (37 ft. lbs.) in sequence. 13. Install the A/C compressor bolts. See Heating and Air Conditioning. 14. Install the drive belt. 15. Install the right splash shield. 16. Install the right front wheel and tire assembly. 17. Install the flex plate housing or transmission converter cover. See Transmission and Drivetrain. 18. Fill the cooling system. See Cooling System. 19. Fill the crankcase with oil. 20. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The engine Oil Pressure Indicator is controlled by the IPC as commanded by the PCM via serial data. The Oil Pressure Indicator will also light when the engine is running if engine oil pressure drops below approximately 13.8 pa (2 psi). As a bulb check procedure, the PCM will command this telltale "ON" for when the IPC and PCM are powered up (ignition in "OFF/UNLOCK," "RUN," or "CRANK" position) and the engine is not running. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Engine Oil Pressure: Customer Interest Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 2470 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Engine Oil Pressure: All Technical Service Bulletins Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Pressure: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 2476 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Technical Service Bulletins > Page 2477 Engine Oil Pressure: Specifications Oil Pressure at 3000 RPM ................................................................................................................... .............................................. 207 kPa (30 psi. min.) Oil Pressure at 900 RPM .................................. ................................................................................................................................... 69 kPa (10 psi. min.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque and Sequence Intake Manifold: Specifications Intake Manifold Torque and Sequence Intake Manifold Bolts/Nuts: 24 Nm (18 ft. lbs.) Intake Manifold to the Cylinder Head Studs: 11 Nm (97 inch lbs.) Throttle Body to the Intake Manifold: 10 Nm (89 inch lbs.) INTAKE MANIFOLD BRACKET NOTE: Finger start all bolts. ^ Tighten bolt (A) to 24 Nm (18 ft. lbs.). ^ Tighten bolt (B) to 26 Nm (19 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque and Sequence > Page 2484 Intake Manifold: Specifications Throttle Body Torque and Sequence Throttle Body Bolts/Nuts ...................................................................................................................... ............................................... 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2485 Intake Manifold: Description and Operation The intake manifold is made of composite plastic. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement (On Vehicle) Intake Manifold: Service and Repair Intake Manifold Replacement (On Vehicle) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the following electrical connectors: ^ Manifold absolute pressure sensor. ^ Intake Air Temperature (IAT) sensor. ^ EVAP Canister Purge solenoid. ^ Fuel injector harness. 3. Disconnect the vacuum hoses from the fuel regulator and the EVAP Canister Purge solenoid to the canister. 4. Remove the air cleaner duct. 5. Remove the accelerator control cable bracket. 6. Remove the stud ended generator mount bolt. 7. Remove the EGR pipe from the EGR adapter. 8. Raise and support the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement (On Vehicle) > Page 2488 9. Remove the intake manifold support brace. 10. Lower the vehicle. 11. Remove the intake manifold retaining nuts and bolts. 12. Remove the intake manifold and the gasket. INSTALLATION PROCEDURE NOTE: The engine and the manifold should be at ambient temperature when assembled. Do not attempt to install a cold manifold on a hot engine. 1. Install the intake manifold and the gasket. If the gasket is damaged, install a new one with the stamped numbers facing towards the manifold surface. 2. Install the intake manifold fasteners. Tighten the fasteners to 24 Nm (18 ft. lbs.). 3. Raise and suitably support the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement (On Vehicle) > Page 2489 4. Install the intake manifold brace. Finger start all bolts. a. Tighten bolt (A) to 24 Nm (18 ft. lbs.). b. Tighten bolt (B) to 26 Nm (19 ft. lbs.). 5. Lower the vehicle. 6. Connect the EGR pipe to the EGR adapter. 7. Install the EGR pipe to the EGR adapter fasteners. Tighten the fasteners to 26 Nm (19 ft. lbs.). 8. Install the stud ended generator mount bolt. 9. Install the accelerator control cable bracket. 10. Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid. NOTE: If the IAT sensor is removed, apply sealant GM P/N 1052080 or equivalent to its threads before installation. 11. Connect the following electrical connections: ^ Manifold absolute pressure sensor. ^ IAT sensor. ^ EVAP canister purge solenoid. ^ Fuel injector harness. 12. Install the air cleaner duct. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation The Check Oil Indicator is controlled by the IPC as commanded by the PCM via serial data. The oil level is monitored by the PCM with an Oil Level Switch. When the PCM determines a low oil condition, it commands the indicator "ON". As a bulb check procedure, the PCM will command this telltale "ON" when the IPC and PCM are powered up (ignition m OFF/UNLOCK," "RUN," or "CRANK" position) and the engine is not running. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The engine Oil Pressure Indicator is controlled by the IPC as commanded by the PCM via serial data. The Oil Pressure Indicator will also light when the engine is running if engine oil pressure drops below approximately 13.8 pa (2 psi). As a bulb check procedure, the PCM will command this telltale "ON" for when the IPC and PCM are powered up (ignition in "OFF/UNLOCK," "RUN," or "CRANK" position) and the engine is not running. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications Crankshaft Main Bearing Seal: Specifications Rear Crankshaft Seal Housing to Block ............................................................................................................................................. 12 Nm (106 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2501 Crankshaft Main Bearing Seal: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the transmission assembly. See Transmission and Drivetrain. 3. Remove the manual transmission, clutch and pressure plate and the clutch cover assembly. 4. Remove the bolts attaching the flex plate to the crankshaft. 5. Remove the oil pan to the crankshaft seal housing bolts. 6. Remove the seal housing to block bolts. 7. Remove the seal housing and gasket. CAUTION: Properly support the seal housing to prevent damage to the seal during removal. Damage to the seal will result in an oil leak. 8. Support the seal housing for the seal removal using two wood blocks of equal thickness. With the wood blocks on a flat surface, position the seal housing and the blocks so that the transmission side of the seal housing is supported across the dowel pin and center bolt holes on both sides of the seal opening. 9. Drive the crankshaft seal evenly out of the transmission side of the seal housing using a small chisel in the relief grooves on the crankshaft side of the seal housing. INSTALLATION PROCEDURE ^ Tools Required J 36005 Rear Crankshaft Seal Installer J 36660 Torque Angle Meter J 33122 Crankshaft Balancer Holder Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2502 1. Replace the oil pan gasket if any of the following conditions exist: ^ Cuts or nicks ^ Deformation ^ Separation from the aluminum carrier 2. Inspect the strips of silicone across the top of the aluminum carrier at the oil pan, at the cylinder block, and at the seal housing three-way joint. 3. If these strips are damaged they may be repaired using Silicone Sealant GM P/N 12345739 or equivalent. Use only enough sealant to restore the silicone strip to its original dimension. 4. Install the oil pan to the seal housing bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 5. Install the flex plate. 6. Install the new bolts or apply Adhesive/Sealant Compound GM P/N 12345493 or equivalent to the bolts being refused. 7. Use the crankshaft balancer holder and the torque angle meter when installing the bolts in order to prevent crankshaft rotation. Tighten the bolts to 30 Nm (22 ft. lbs.) and rotate to 45 degrees. 8. Install the manual transmission, clutch and pressure plate and clutch cover assembly. See Transmission and Drivetrain. 9. Install the transmission assembly. See Transmission and Drivetrain. 10. Connect the negative battery cable. 11. Start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2503 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine front cover. CAUTION: The engine front cover could be damaged if it is not properly supported during seal removal. 3. Support the front cover and drive the oil seal out the timing chain side of the cover. INSTALLATION PROCEDURE ^ Tool Required - J 36010 Front Cover Crankshaft Seal Installer, or equivalent. 1. Install the seal into the front cover by driving it in from the timing chain side using crankshaft seal installer. The crankshaft seal installer will properly position the seal in the front cover, 2. Install the engine front cover. 3. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Thermostat Gasket: Customer Interest Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2515 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2516 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Thermostat Gasket: All Technical Service Bulletins Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2522 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2523 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust Valve Guide Seal: Service and Repair Exhaust Removal ^ Tools Required, or equivalent: J 36588 Valve Spring Compressor T-Bolt J 5892-D Valve Spring Depressor J 36011 Spark Plug Connector Assembly Remover J 36017 Valve Guide Seal Remover NOTE: Any time the camshaft housing to the cylinder head bolts are loosened or removed, the camshaft housing to the cylinder head gasket must be replaced. 1. Disconnect the negative battery cable. 2. Disconnect the ignition coil and module assembly electrical connections. 3. Remove the ignition coil and module assembly to the camshaft housing bolts. 4. Remove the assembly by pulling straight up. 5. Use the spark plug connector assembly remover in order to remove the connector assembly if the connector assembly is stuck to the spark plugs. 6. Use the tool by first twisting then pulling up on the connector assembly. 7. Disconnect the electrical connection from the oil pressure switch. 8. Remove the transmission fluid level indicator tube assembly from the exhaust camshaft cover and position aside (automatic transmission only). 9. Disconnect the timing chain housing at the exhaust camshaft housing, but do not remove it from the vehicle. CAUTION: Turn the camshaft housing upside down as soon as it is removed from the cylinder head. The lifters will fall out of the camshaft housing if it is not turned upside down. The lifters can be damaged if they fall out and hit a hard surface. NOTE: Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2528 10. Remove the exhaust camshaft housing to the cylinder head bolts. 11. Remove the exhaust camshaft housing. 12. Remove the camshaft housing gasket. 13. Remove the spark plug. 14. Using a suitable adapter, apply air pressure to the cylinder. 15. Compress the valve spring. Use the valve spring depressor and the valve spring compressor t-bolt. 16. Disassemble the following components: ^ The valve keys. ^ The retainer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2529 ^ The spring. ^ The valve seal using valve guide seal remover. ^ The rotator (intake). ^ The valve spring seat (exhaust). 17. Assemble the following components: ^ The rotator (intake). ^ The valve spring seat (exhaust). ^ A new, clean and dry valve seal. Push the seal on by hand in order to ensure that the seal is fully seated. ^ The spring and retainer. Use the valve spring compressor t-bolt, and the valve spring depressor in order to compress the valve spring. ^ The valve keys. 18. Inspect for proper valve key seating. Installation ^ Tools Required, or equivalent - J 36660 Torque Angle Meter 1. Remove the air line adapter. 2. Install the spark plug. CAUTION: Carefully roll the camshaft housing right side up as it is installed onto the cylinder head. The lifters can be damaged if they fall out and hit a hard surface. 3. Install the exhaust camshaft housing. 4. Apply Pipe Sealant GM P/N 1052080 or equivalent to the camshaft housing retaining bolt threads. 5. Use the torque angle meter in order to install the bolts. Install the bolts in sequence. Tighten the bolts to 15 Nm (11 ft. lbs.) plus 90 degrees. 6. Install the timing chain housing to the camshaft housing and timing chain. 7. Install the transmission fluid level indicator tube assembly to the exhaust camshaft cover. 8. Connect the electrical connection to the oil pressure switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2530 9. Reinstall any spark plug boot connector assembly that stuck to a spark plug, back onto the ignition coil and module assembly. 10. Place the ignition coil and module assembly over the spark plugs and push straight down. 11. Clean any lubricant that is present on the ignition coil and module assembly to the camshaft housing bolts. 12. Apply Pipe Sealant GM P/N 1052080 or equivalent onto the ignition coil and module assembly to the camshaft housing bolts. 13. Install the ignition coil and module assembly to the camshaft housing bolts. Tighten the bolts to 15 Nm (11 ft. lbs.) plus 30 degrees. 14. Connect the electrical connector to the ignition coil and module assembly. 15. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2531 Valve Guide Seal: Service and Repair Intake Removal ^ Tools Required, or equivalent: J 36588 Valve Spring Compressor T-Bolt J 5892-D Valve Spring Depressor J 36011 Spark Plug Connector Assembly Remover J 36017 Valve Guide Seal Remover NOTE: Any time the camshaft housing to the cylinder head bolts are loosened or removed, the camshaft housing to the cylinder head gasket must be replaced. 1. Disconnect the negative battery cable. 2. Disconnect the ignition coil and module assembly electrical connections. 3. Remove the ignition coil and module assembly to the camshaft housing bolts. Remove the assembly by pulling straight up. Use the spark plug connector assembly remover in order to remove the connector assembly if it is stuck to the spark plugs. Use the tool by first twisting then pulling up on the connector assembly. 4. Remove the camshaft position sensor connector. 5. Remove the power steering pump. see Steering and Suspension. 6. Disconnect the vacuum line from the fuel pressure regulator and the fuel injector harness connector. 7. Remove the fuel line retaining clamp from the bracket on top of the intake camshaft housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2532 8. Remove the fuel rail to the camshaft housing retaining bolts. 9. Remove the fuel rail from the cylinder head. 10. Cover the injector openings in the cylinder head. 11. Cover the injector nozzles. 12. Leave the fuel lines attached and position the fuel rail aside (on top of the master cylinder). 13. Disconnect the timing chain housing at the intake camshaft housing but do not remove from the vehicle. 14. Remove the camshaft to cylinder head retaining bolts. CAUTION: Turn the camshaft housing upside down as soon as it is removed from the cylinder head. The lifters will fall out of the camshaft housing if it is not turned upside down. the lifters can be damaged if they fall out and hit a hard surface. NOTE: Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts. 15. Remove the camshaft housing. 16. Remove the camshaft housing gasket. 17. Remove the spark plug. 18. Using a suitable adapter, apply air pressure to the cylinder. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2533 19. Compress the valve spring. Use the valve spring depressor and the valve spring compressor t-bolt. 20. Disassemble the following components: ^ The valve keys. ^ The retainer. ^ The spring. ^ The valve seal using valve guide seal remover. ^ The rotator (intake). ^ The valve spring seat (exhaust) 21. Assemble the following components: ^ The rotator (intake). ^ The valve spring seat (exhaust). ^ A new, clean and dry valve seal. Push the seal on by hand in order to ensure that the seal is fully seated. ^ The spring and retainer. Use the valve spring depressor and the valve spring compressor t-bolt in order to compress the valve spring. ^ The valve keys. 22. Inspect for proper valve key seating. Installation ^ Tools Required - J 36660 Torque Angle Meter, or equivalent. 1. Remove air line adapter. 2. Install the spark plug. CAUTION: Carefully roll the camshaft housing right side up as it is installed onto the cylinder head. The lifters can be damaged if they fall out and hit a hard surface. 3. Install the camshaft housing. 4. Install the camshaft housing gasket. 5. Apply Pipe Sealant GM P/N 1052080 or equivalent to the camshaft housing retaining bolt threads. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2534 6. Install the camshaft housing bolts. 7. Using the torque angle meter, install the bolts in sequence. Tighten the bolts to 15 Nm (11 ft. lbs.) + 90 degrees. 8. Install the timing chain housing and the timing chain. 9. Uncover the fuel injectors. 10. Install new injector O ring seals. Lubricate the O ring seals with engine oil. 11. Uncover the injector openings in the cylinder head and install the fuel rail onto the cylinder head. 12. Install the fuel rail to the camshaft housing bolts. Tighten the bolts to 26 Nm (19 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Exhaust > Page 2535 13. Connect the fuel line retaining clamp and the retainer to the bracket on top of the camshaft housing. 14. Connect the vacuum line to the fuel pressure regulator. 15. Install the fuel injector harness connector. 16. Install the camshaft position sensor connector. NOTE: When reinstalling the power steering pump, apply a 3 mm bead of GM P/N 12346286 sealer or equivalent to the joint at the end of the camshaft housing halves before installation of the power steering pump and the pump face seal. 17. Install the power steering pump assembly. See Steering and Suspension. 18. Reinstall any spark plug boot connector assembly that stuck to a spark plug back onto the ignition coil and module assembly. 19. Place the ignition coil and module assembly over the spark plugs and push straight down. 20. Clean any lubricant that is present on the ignition coil and module assembly to the camshaft housing bolts. 21. Apply Pipe Sealant GM P/N 1052080 or equivalent onto the ignition coil and module cover assembly to the camshaft housing bolts. Tighten the bolts to 15 Nm (11 Lb ft) + 30 degrees. 22. Connect the electrical connector to the ignition coil and module assembly. 23. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2536 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Engine - Correction To Balance Shaft Holding Tool Balance Shaft: Technical Service Bulletins Engine - Correction To Balance Shaft Holding Tool File In Section: 6 - Engine Bulletin No.: 77-61-13 Date: August, 1997 SERVICE MANUAL UPDATE Subject: Section 6A - Engine Mechanical - Balance Shaft Holding Tool Models: 1997 Chevrolet Cavalier, Malibu 1997 Pontiac Sunfire, Grand Am 1997 Buick Skylark 1997 Oldsmobile Achieva with 2.4L Engine (VIN T - RPO LD9) In the 1997 Service Manual Section 6A or the Engine Section, the Balance Shaft Holding Tool was incorrectly specified as J 38122, on Pages 6A-131, 132, 134, and 6A-136. The correct tool number for the Balance Shaft Holding Tool is J 41088. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > General Balance Shaft: Specifications General Bore Roundness .................................................................................................................................. .......................................... 0.025 mm (0.0009 inches) Bearing Thickness .................................................................................................................................................. 1.500-1.508 mm (0.0590-0.0593 inches) Bearing I.D. ....................................................................................................................................................... 30.019-30.061 mm (1.1819-1.1835 inches) Endplay .......................................................................... ....................................................................................... 0.185-0.455 mm (0.0073-0.0179 inches) Housing Flatness Maximum ......................................................................................................................................................... 0.076 mm (0.0030 inches) Housing Bore ..................................................................................................................................................... 33.025-33.050 mm (1.3001-1.3021 inches) Journal Roundness Maximum ...................................................................................................................................................... 0.005 mm (0.0002 inches) Journal Taper ........................................................................................................................................................... 0.000-0.010 mm (0.000-0.0004 inches) Shaft Journal O.D. ............................................................................................................................................. 29.950-29.975 mm (1.1791-1.1801 inches) Shaft Groove Width ....................................................................................................................................................... 3.23-3.40 mm (0.127-0.134 inches) Thrust Plate Thickness ........................................................................................................................................... 2.945-3.045 mm (0.1159-0.1199 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > General > Page 2551 Balance Shaft: Specifications Tightening Balance Shaft: To Block Bolts (13 mm hex) ................................................................................................................ ................................................ 25 Nm (18 ft. lbs.) To Block Bolts (15 mm hex) .................................. .............................................................................................................................. 53 Nm (39 ft. lbs.) To Block Bolts (18 mm hex) ...................................................................................................................................................... 40 Nm (30 ft. lbs.) + 60° To Crankshaft .................................................................................................... ..................................................................... 175 Nm (129 ft. lbs.) + 90° To Housing Bolts (8 mm hex) ..................................................................................................................................................... 10 Nm (11 ft. lbs.) + 45° Cover Nut and Bolt .............................................................................................................................. ............................................... 13 Nm (115 inch lbs.) Housing Bolts (10 mm hex) ............................................................................................................................................................ 15 Nm (11 ft. lbs.) + 40° Thrust Plate To The Balance Shaft Housing ....................................................................................................................................... 13 Nm (115 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > Page 2552 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul Balance Shaft: Service and Repair Balance Shaft - Overhaul DISASSEMBLY 1. Remove the oil pump pick-up screen. Pry it out with a suitable tool. 2. Loosen all of the housing bolts. 3. Separate the balance shaft housings. 4. Remove the balance shaft and gear subassemblies from the housing. 5. Carefully remove the bearing halves from the housing. Do not scratch or gouge the housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2555 6. Remove the thrust plate bolts. 7. Remove the thrust plate. ASSEMBLY 1. Install the thrust plate. 2. Install the thrust plate bolts. Tighten the thrust plate bolts to 13 Nm ( 115 inch lbs. ). 3. Carefully install the bearing halves into the housing. Do not scratch or gouge the housing or the bearings. 4. Lubricate the bearings, shafts and gears with GM P/N 9985705 or equivalent. 5. Install the balance shaft and gear assemblies into the housing. 6. Ensure that the timing marks on the balance shaft gears are lined up. 7. Install the upper housing half to the lower housing half. 8. Install the housing fasteners. Tighten the fasteners to 5 Nm ( 44 inch lbs. ). 9. Tighten the fasteners to final specifications after the housing assembly has been installed on the engine. CAUTION: Do not install the oil pump pick-up screen until the housing fasteners have been tightened to final specifications. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2556 Balance Shaft: Service and Repair Balance Shaft - Removal Removal Tools Required: - J 41088 Balance Shaft, Holding Plate, or equivalent. 1. Disconnect the negative battery cable. 2. Remove the engine oil pan. 3. Remove the balance shaft chain cover nut and bolt. 4. Remove the balance shaft chain cover. 5. Loosen but do remove the balance shaft chain tensioner. 6. Remove the oil pump cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2557 7. Remove the oil pump assembly. 8. Rotate the engine crankshaft until the number one piston is at TDC. 9. Use balance shaft, holding plate to prevent the balance shafts from turning while loosening the bolt. NOTE: The balance shaft driven sprocket bolt is left-hand threaded and must be loosened by rotating it in a clockwise direction. 10. Remove the balance shaft driven sprocket bolt. NOTE: Mark the surface of the driven sprocket if it is going to be reused. This will insure that the chain continues to ride on the same tooth surface. If a new driven sprocket will be installed, either surface can be placed against the shaft. 11. Remove the driven sprocket from the shaft. 12. Remove the balance shaft assembly fasteners and remove the assembly to the bench. 13. Check the balance shaft end play prior to disassembling the balance shaft housing. ^ Set up the indicator to read off the back of the shafts. ^ Press against the one shaft and note the movement. ^ Repeat the above step on the other shaft. ^ Compare against specifications. ^ If out of specs, check the thrust plate for wear. Replace if necessary. If the end play is out of specs and the thrust plate is not worn, replace the balance shafts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2558 Balance Shaft: Service and Repair Installation Installation 1. Install the balance shaft assembly to the engine block. Use GM P/N 123454493, or equivalent on the housing to block bolts. Tighten the balance shaft assembly to the engine block bolts to specifications. 2. Install the balance shaft driven sprocket. Tighten the bolt to 30 Nm (22 ft. lbs.) + 45°. Use balance shaft, holding plate to hold balance shafts in the correct timed location. 3. Install the balance shaft chain tensioner and torque to specifications. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2559 4. Install the balance shaft chain cover. Tighten the nut and the bolt to 13 Nm ( 115 inch lbs. ). 5. Install the oil pan gasket and the oil pan. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2560 Balance Shaft: Service and Repair Timing Balance Shafts to Engine Timing Balance Shafts to Engine Tools Required: J 38122 Balance Shaft Holder J 36660 Torque Angle Meter 1. Install the balance shaft assembly to the block. Use Loctite 272 GM P/N 12345493 on the housing assembly to the block bolts. 2. If the balance shaft housing was disassembled, loosely assemble the housing assembly to the block. 3. Install the balance shaft assembly to the block. Use Loctite 272 GM P/N C12345493 on the housing assembly to the block bolts. 4. If the balance shaft housing was disassembled, loosely assemble the housing assembly to the block. 5. Tighten the housing fasteners in sequence. Tighten ^ Tighten fasteners 1, 2, 4, 5, 6 and 7 to 15 Nm ( 11 lb ft ) + 40 degrees. ^ Tighten fasteners 3 and 8 to 10 Nm ( 89 lb in ) + 40 degrees. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2561 6. Tighten the housing assembly to block bolts in sequence. Tighten ^ Tighten bolts 1,2 and 4 to 25 Nm ( 18 lb ft ) + 70 degrees. ^ Tighten bolt 3 to 40 Nm ( 30 lb in ) + 60 degrees. ^ Tighten bolt 5 to 53 Nm ( 39 lb ft ). 7. Ensure that the balance shafts spin freely. 8. If the balance shaft housing was disassembled, install the oil pump pick-Lip screen into the housing. Lightly tap it into place with a plastic hammer. Important: If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise. 9. Install the timed balance shaft and housing assembly to the engine using the following steps: 9.1. Place the number one piston at TDC. 9.2. Rotate the crankshaft 90 degrees. 9.3. Install the J 38122 on to the balance shaft assembly to ensure the shafts do not rotate while the driven sprocket bolt is tightened. Notice: A new balance shaft driven sprocket bolt must be used any time the bolt is removed. If a new bolt is not used, the balance shaft sprocket may slip allowing the balance shafts to become mistimed and cause engine vibration. Important: The surface that was marked during disassembly of the driven sprocket must show if it is going to be reused. This will insure that the chain continues to ride on the same surface. If a new driven sprocket will be installed, either surface can be placed against the shaft. 10. Install the driven sprocket to the shaft. Important: The balance shaft driven sprocket bolt is left hand threaded and must be tightened by rotating it in a counter clockwise direction. 11. Install the driven sprocket bolt. Finger tighten. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Balance Shaft - Overhaul > Page 2562 12. Install the balance shaft chain guide. 13. Press the chain guide tightly against the chain. 14. Tighten the chain tensioner bolt. Tighten ^ Tighten the chain tensioner bolt to 13 Nm ( 115 lb in ). 15. Tighten the balance shaft driven sprocket bolt. Tighten ^ Tighten the driven sprocket bolt to 30 Nm ( 22 lb ft ). Use the J C36660 in order to rotate the bolt an additional 45 degrees. 16. Remove the J 38122 from the balance shaft housing assembly. 17. Loosen the balance shaft chain guide bolt. Important: A brass feeler gauge needs to be used in order to ensure correct measurements are obtained. If a steel gauge is used, it will not bend to conform to the guide and will cause incorrect measurements. 18. Adjust the balance shaft drive chain tension. Insert a 1 mm (0.040 in) brass feeler gauge between the chain guide and the chain. 19. Press the guide against the chain using about three pounds of force. 20. Install the chain tensioner bolt. Tighten ^ Tighten the chain tensioner bolt to 13 Nm ( 115 lb in ). 21. Install the balance shaft chain cover. 22. Install the balance shaft chain cover nut and bolt. Tighten ^ Tighten the chain cover nut and bolt to 13 Nm ( 115 lb in ). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Page 2563 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Bearing > Component Information > Specifications Balance Shaft Bearing: Specifications Bearing Clearance ................................................................................................................................................. 0.044-0.111 mm (0.0017-0.0044 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain > Component Information > Specifications Balance Shaft Chain: Specifications Chain Slack [1] .................................................................................................................................... .............................................. 1.0 mm (0.040 inches) Maximum Groove Depth .................................. ................................................................................................................................. 2.5 mm (0.100 inches) [1] With 6 lb Of Pressure Applied To The Guide Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement Balance Shaft Chain: Service and Repair Tensioner Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine oil pan. 3. Remove the balance shaft chain cover. 4. Remove the balance shaft chain tensioner bolt. 5. Remove the balance shaft chain tensioner. INSTALLATION PROCEDURE 1. Install the balance shaft chain tensioner. NOTE: A brass feeler gauge needs to be used in order to ensure correct measurements are obtained. If a steel gauge is used, it well not bend in order to conform to the guide and it will allow for incorrect measurements. 2. Adjust the balance shaft drive chain tension by inserting a 1 mm (0.040 inches) brass feeler gauge between the chain guide and the chain. Press the guide against the chain using about three pounds of force. 3. Tighten the chain tensioner fastener. Tighten the bolts to 13 Nm (115 inch lbs.). 4. Install the balance shaft chain cover. 5. Install the balance shaft chain cover nut and bolt. Tighten the nut and bolt to 13 Nm (115 inch lbs.). 6. Install the oil pan gasket. 7. Install the oil pan. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement > Page 2572 Balance Shaft Chain: Service and Repair Chain Replacement Removal Tools Required, or equivalent: J 38122 Harmonic Balancer Holder J 24420-B Harmonic Balance Puller NOTE: Anytime the drive chain is replaced the drive and driven sprockets also need to be replaced. 1. Disconnect the negative battery cable. 2. Remove the Engine/Transmission assembly from the vehicle. 3. Support the engine with chains and a suitable hoist. 4. Remove the starter motor. See Starting and Charging. 5. Remove the torque converter to the flex plate bolts. Hold the crankshaft balancer with the harmonic balancer holder. 6. Remove the Transmission selector cable. 7. Remove the engine torque strut bracket. 8. Remove the Transmission to the engine brace. 9. Remove the Transmission from the engine. See Transmission and Drivetrain. 10. Remove the flex plate. See Transmission and Drivetrain. 11. Clean the flex plate bolt threads and crankshaft threads with nylon bristle brush. 12. Remove the crankshaft balancer pulley. Use the harmonic balancer holder and the harmonic balance puller. 13. Attach the engine stand fixture to the engine. Install the engine on the stand. 14. Remove the ignition coil and module assembly. 15. Remove the spark plugs. See Powertrain Management. 16. Remove the engine front cover. 17. Rotate the engine to the TIMED position and remove the timing chain. See: Timing Chain/Service and Repair 18. Remove the timing chain housing. 19. Rotate the engine on the engine stand 180° in order to access oil pan. 20. Remove the oil pan. 21. Remove the oil pan gasket. 22. Remove the balance shaft assembly. 23. Remove the crankshaft. 24. Remove the balance shaft drive chain. Installation 1. Install the balance shaft drive chain. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement > Page 2573 2. Install the crankshaft. 3. Install the balance shaft assembly. 4. Time the balance shaft. 5. Install the oil pan gasket. 6. Install the oil pan. 7. Rotate the engine 180 degrees on the stand in order to install the timing chain housing and the other components. 8. Install the timing chain. 9. Install the timing chain housing. 10. Install the front timing chain cover. Install the upper engine mount bracket. See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair 12. Install the lower engine strut mount bracket. 13. Install the spark plugs. See Powertrain Management. 14. Install the ignition coil and module assembly. 15. Connect the engine to the chain hoist and remove the engine stand fixture from the engine block. 16. Install the crankshaft balancer pulley. 17. Install the flex plate to the engine. See Transmission and Drivetrain. 18. Connect the Transmission to the engine. See Transmission and Drivetrain. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain > Component Information > Service and Repair > Tensioner Replacement > Page 2574 19. Install the Transmission to the engine brace. 20. Install the Transmission to the engine brace bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 21. Install the Transmission selector cable. See Transmission and Drivetrain. 22. Install the torque converter to the flex plate bolts. 23. Install the starter motor assembly to the engine. See Starting and Charging. 24. Install the Engine/Transmission assembly. 25. Refill all fluid levels to specification. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Gear > Component Information > Specifications > General Balance Shaft Gear: Specifications General Gear Diameter ................................................................................................................................................... 61.050-61.145 mm (2.4035-2.4073 inches) Gear Backlash ....................................................................................................................................................... 0.008-0.086 mm (0.0003 0.0034 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Gear > Component Information > Specifications > General > Page 2579 Balance Shaft Gear: Specifications Tightening Balance Shaft Driven Sprocket Bolt (left hand thread) ........................................................................ ................................................................................................... 30 Nm (22 ft. lbs.) + 45° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Cam Gear Torque Specifications Camshaft Gear/Sprocket: Specifications Cam Gear Torque Specifications Camshaft Sprocket Retaining Bolt ............................................................................................................................................................ 70 Nm (52 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Cam Gear Torque Specifications > Page 2584 Camshaft Gear/Sprocket: Specifications Tightening Camshaft Sprocket to the Camshaft Bolt .................................................................................................................................................. 70 Nm (52 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation Camshaft Gear/Sprocket: Service and Repair Installation NOTE: GM does not provide timing chain timing marks, or information to perform timing chain service without the special tools shown in this procedure. TOOL REQUIRED ^ J 36800 Camshaft Sprocket Timing Alignment Pin ^ J 39579 Camshaft Sprocket Wrench CAUTION: Failure to follow this procedure could result in severe engine damage. 1. Install the intake camshaft sprocket onto the camshaft with the marked surface showing. 2. Install the intake camshaft sprocket Retaining bolt and washer. Tighten the bolt to 70 Nm (52 ft. lbs.) while holding the sprocket with the camshaft sprocket wrench. 3. Use Adhesive/Sealant Compound GM P/N 12345493 or equivalent on the camshaft sprocket bolt. 4. Install the camshaft sprocket timing alignment pin through the holes in the camshaft sprockets into the holes in the timing chain housing in order to position the camshaft for correct timing. 5. If the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins, use the following procedure: a. The crankshaft must be rotated 90 degrees clockwise off of the TDC in order to give the valves adequate clearance to open. b. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to the top dead center. WARNING: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. NOTE: The side of the timing chain that was marked during removal must be showing when the chain is installed. 6. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2587 7. Set the camshaft sprockets at the timed position and use the following procedure in order to install the timing chain: a. Remove the alignment dowel pin from the intake camshaft. b. Use the camshaft sprocket wrench in order to rotate the intake camshaft sprocket counter clockwise enough to slide the timing chain over the intake camshaft sprocket. c. Release the camshaft sprocket wrench. The length of the chain between the two camshaft sprockets will tighten. d. If properly timed the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 8. Leave the alignment dowel pins installed. 9. Raise and support the vehicle. 10. With the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and the recheck marks. 11. In order to reload the timing chain tensioner assembly to its zero position, form a keeper from a piece of heavy gauge wire. 12. Apply a slight force on the tensioner blade in order to compress the plunger. 13. Insert a small screwdriver into the reset access hole, and pry the ratchet pawl away from the ratchet teeth while forcing the plunger completely in the hole. 14. Install the keeper between the access hole and the blade. 15. Install the tensioner assembly to the chain housing. Recheck the plunger assembly installation, it is correctly installed when the long end is toward the crankshaft. 16. Install the timing chain tensioner bolts. Tighten the bolts to 10 Nm (89 inch lbs.). 17. Lower the vehicle enough to reach and remove the alignment dowel pins. 18. Rotate the crankshaft clockwise (normal rotation) two full rotations. 19. Align the crankshaft keyway with the mark on the cylinder block and reinstall alignment dowel pins. 20. Alignment dowel pins will slide in easily if the engine is timed correctly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2588 21. Install the timing chain guides. 22. Install the engine front cover. 23. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2589 Camshaft Gear/Sprocket: Service and Repair Removal NOTE: GM does not provide timing chain timing marks, or information to perform timing chain service without the special tools shown in this procedure. ^ Tools Required, or equivalent: J 36800 Camshaft Sprocket Timing Alignment Pin J 39579 Camshaft Sprocket Wrench NOTE: Before removing the timing chain, read the entire procedure. The timing chain and the crankshaft sprocket must be marked in order to insure reassembly with the same side facing out at the time of reassembly. CAUTION: The timing chain is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. 1. Disconnect the negative battery cable. 2. Remove the engine front cover. 3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes line up with the holes in the timing chain housing. 4. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the "Timed" position. 5. Remove the timing chain guides. 6. Raise and support the vehicle. 7. Ensure that all of the slack in the timing chain is above the tensioner assembly. 8. Remove the timing chain tensioner. 9. The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward. CAUTION: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur. 10. If difficulty is encountered in removing the timing chain tensioner shoe, use the following procedure in order to remove the intake camshaft sprocket. a. Lower the vehicle. b. Hold the intake camshaft sprocket with the camshaft sprocket wrench and remove the sprocket bolt and washer. c. Remove the washer from the bolt and rethread the bolt back into the camshaft by hand (the bolt provides a surface to push against). d. Remove the intake camshaft sprocket. Use a three-jaw puller in the three relief holes in the sprocket. 11. Remove the tensioner assembly retaining bolts and tensioner. CAUTION: The timing chain and the crankshaft sprocket must be marked prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2590 12. Mark the crankshaft sprocket and the timing chain outer surface. 13. Remove the timing chain. 14. Clean the old sealant off of the bolt with a wire brush. 15. Clean the threaded hole in the camshaft with a round nylon bristle brush. 16. Inspect the parts for wear and replace the parts as necessary. Some scoring of the timing chain shoe and the guides is normal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Gear/Hub Torque Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Gear/Hub Torque Specifications Balancer to the Crankshaft .......................................................................................................................................................... 175 Nm (129 ft. lbs.) + 90° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications > Crankshaft Gear/Hub Torque Specifications > Page 2595 Crankshaft Gear/Sprocket: Specifications Crankshaft Pully/Hub Torque Specification Crankshaft Balancer to the Crankshaft ............................................................................................................................................ 175 Nm (129 lb ft) +90° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation Crankshaft Gear/Sprocket: Service and Repair Installation CAUTION: Failure to follow this procedure could result in severe engine damage. 1. Install the intake camshaft sprocket onto the camshaft with the marked surface showing. 2. Install the intake camshaft sprocket Retaining bolt and washer. Tighten the bolt to 70 Nm (52 ft. lbs.) while holding the sprocket with the camshaft sprocket wrench. 3. Use Adhesive/Sealant Compound GM P/N 12345493 or equivalent on the camshaft sprocket bolt. 4. Install the camshaft sprocket timing alignment pin through the holes in the camshaft sprockets into the holes in the timing chain housing in order to position the camshaft for correct timing. 5. If the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins, use the following procedure: a. The crankshaft must be rotated 90 degrees clockwise off of the TDC in order to give the valves adequate clearance to open. b. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to the top dead center. WARNING: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. NOTE: The side of the timing chain that was marked during removal must be showing when the chain is installed. 6. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2598 7. Set the camshaft sprockets at the timed position and use the following procedure in order to install the timing chain: a. Remove the alignment dowel pin from the intake camshaft. b. Use the camshaft sprocket wrench in order to rotate the intake camshaft sprocket counter clockwise enough to slide the timing chain over the intake camshaft sprocket. c. Release the camshaft sprocket wrench. The length of the chain between the two camshaft sprockets will tighten. d. If properly timed the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 8. Leave the alignment dowel pins installed. 9. Raise and support the vehicle. 10. With the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and the recheck marks. 11. In order to reload the timing chain tensioner assembly to its zero position, form a keeper from a piece of heavy gauge wire. 12. Apply a slight force on the tensioner blade in order to compress the plunger. 13. Insert a small screwdriver into the reset access hole, and pry the ratchet pawl away from the ratchet teeth while forcing the plunger completely in the hole. 14. Install the keeper between the access hole and the blade. 15. Install the tensioner assembly to the chain housing. Recheck the plunger assembly installation, it is correctly installed when the long end is toward the crankshaft. 16. Install the timing chain tensioner bolts. Tighten the bolts to 10 Nm (89 inch lbs.). 17. Lower the vehicle enough to reach and remove the alignment dowel pins. 18. Rotate the crankshaft clockwise (normal rotation) two full rotations. 19. Align the crankshaft keyway with the mark on the cylinder block and reinstall alignment dowel pins. 20. Alignment dowel pins will slide in easily if the engine is timed correctly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2599 21. Install the timing chain guides. 22. Install the engine front cover. 23. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2600 Crankshaft Gear/Sprocket: Service and Repair Removal ^ Tools Required, or equivalent: J 36800 Camshaft Sprocket Timing Alignment Pin J 39579 Camshaft Sprocket Wrench NOTE: Before removing the timing chain, read the entire procedure. The timing chain and the crankshaft sprocket must be marked in order to insure reassembly with the same side facing out at the time of reassembly. CAUTION: The timing chain is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. 1. Disconnect the negative battery cable. 2. Remove the engine front cover. 3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes line up with the holes in the timing chain housing. 4. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the "Timed" position. 5. Remove the timing chain guides. 6. Raise and support the vehicle. 7. Ensure that all of the slack in the timing chain is above the tensioner assembly. 8. Remove the timing chain tensioner. 9. The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward. CAUTION: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur. 10. If difficulty is encountered in removing the timing chain tensioner shoe, use the following procedure in order to remove the intake camshaft sprocket. a. Lower the vehicle. b. Hold the intake camshaft sprocket with the camshaft sprocket wrench and remove the sprocket bolt and washer. c. Remove the washer from the bolt and rethread the bolt back into the camshaft by hand (the bolt provides a surface to push against). d. Remove the intake camshaft sprocket. Use a three-jaw puller in the three relief holes in the sprocket. 11. Remove the tensioner assembly retaining bolts and tensioner. CAUTION: The timing chain and the crankshaft sprocket must be marked prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Installation > Page 2601 12. Mark the crankshaft sprocket and the timing chain outer surface. 13. Remove the timing chain. 14. Clean the old sealant off of the bolt with a wire brush. 15. Clean the threaded hole in the camshaft with a round nylon bristle brush. 16. Inspect the parts for wear and replace the parts as necessary. Some scoring of the timing chain shoe and the guides is normal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair Timing Belt: Service and Repair GM does not specify if this engine is an interference engine or not. To be safe, always observe the following precautions. If cylinder head is installed on the cylinder block: - DO NOT turn the crankshaft or camshaft if the timing belt/chain is not installed or if the camshaft timing has not been confirmed to be correct. - DO NOT rotate engine backwards. - If a broken or "jumped" timing belt/chain is suspected, DO NOT use the starter to crank the engine. - If a "catch" is felt when rotating the engine by hand, DO NOT attempt force the engine to rotate past the "catch". If cylinder head is removed (overhead cam engines): - Do not set cylinder head on a flat surface with combustion chamber down. When re-installing a cylinder head: - Confirm that the crankshaft AND camshaft gears align with their respective timing marks or confirm that all shafts are set to TDC for cylinder # 1 BEFORE placing the cylinder head onto the cylinder block. If the timing chain/belt has broken of "jumped time" with the engine running, always check for bent valves by pressurizing each cylinder with air with it's valves in the closed position. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Timing Chain Tensioner - Service Procedure Technical Service Bulletin # 67-61-22A Date: 980701 Timing Chain Tensioner - Service Procedure File In Section: 6 Engine Bulletin No.: 67-61-22A Date: July, 1998 SERVICE MANUAL UPDATE Subject: Section 6A - Engine Mechanical - Timing Chain Tensioner Service Procedure Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva 1997-98 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN T - RPO LD9) This bulletin is being revised to clarify the service procedure in regards to timing chain tensioner installation and to include the 1998 model year. Please discard Corporate Bulletin Number 67-61-22 (Section 6 - Engine). This bulletin is being issued to update the service procedures for the timing chain tensioner on LD9 engines built after September 29, 1996. These engines have a new two-piece timing chain tensioner. Important: The new two-piece timing chain tensioner is not interchangeable with the previous version. Do not attempt to replace the one-piece timing chain tensioner with the two piece design. Timing Chain, Sprockets, and Tensioner Removal Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing chain sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. Procedure Important: Read the entire procedure before removing the timing chain. 1. Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. Ensure that this is done in order to prevent noise and increased wear on the chain. 2. Remove the timing chain guides. See Figure 1. 3. Remove the timing chain tensioner block and tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Timing Chain Tensioner - Service Procedure > Page 2609 4. Remove the timing chain tensioner shoe from the stud. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud. See Figure 2. 5. Remove the timing chain. See Figure 3. 6. Inspect the parts for wear, replace them as required. 7. Replace the timing chain shoe or the guides if the scoring exceeds 1.12 mm (0.045 in.). 8. Remove the timing chain tensioner plunger from the tensioner body. When the timing chain tensioner body was removed from the housing, the plunger should have extended to full length exposing the drain holes. If the plunger did not extend, replace the tensioner assembly. 9. Place the tensioner plunger on its side on a shop rag to allow the oil to drain from the inside of the tensioner. Timing Chain, Sprockets, and Tensioner Installation Tools Required J 39579 Camshaft Sprocket Wrench J 36008-A Camshaft Sprocket Alignment Pins Important: Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil-seal-to-crankshaft alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Timing Chain Tensioner - Service Procedure > Page 2610 1. Install J 36008-A through holes in the camshaft sprockets and into holes in the timing chain housing. This will position the camshaft for correct timing. See Figure 4. 2. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn to install the alignment dowel pins: Notice: Failure to follow this procedure could result in severe engine damage. a. The crankshaft must be rotated 90 clockwise off of TDC to give the valves adequate clearance to open. b. Once the camshafts are in position and the J 36008-A Camshaft Sprocket Alignment Pins are installed, rotate the crankshaft counter-clockwise back to TDC. Notice: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. Important: The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. 3. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 4. Remove the J 36008-A Camshaft Sprocket Alignment Pin from the intake camshaft. Use J 39579 in order to rotate the intake camshaft sprocket counter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. 5. Release J 39579. The length of the chain between the two camshaft sprockets will tighten. 6. If properly timed, the J 36008-A Camshaft Sprocket Alignment Pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 7. Leave the alignment dowel pins installed. 8. The keyway on the crankshaft and the mark on the cylinder block should be aligned, with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward; remove the slack and recheck the marks. See Figure 4. 9. Use the following steps in order to reload the tensioner assembly to its zero position: a. Assemble the tensioner plunger and the tensioner body. b. With the tensioner plunger fully extended, turn the tensioner and tensioner body upside down on a bench or other flat surface. A metal workbench is best for this. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Timing Chain Tensioner - Service Procedure > Page 2611 c. With the plunger face against the workbench, press firmly on the bottom of the tensioner body, compress the tensioner plunger until it is seated flush in the tensioner. See Figure 5. 10. Install the tensioner body and plunger to the chain housing. 11. Install the timing chain tensioner shoe on the stud. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. 12. Tighten the timing chain tensioner body bolts. Do not over-tighten. Tighten Tighten the bolts to 10 N.m (89 lb in.) Refer to Fastener Notice in General Information. 13. Release the timing chain tensioner plunger. Notice: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started. 14. Using a flat-blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of timing chain tensioner plunger. 15. Depress the timing chain tensioner plunger until it is bottomed out in the bore of the timing chain tensioner. If the timing chain tensioner cannot be depressed, it is not properly loaded and the procedure for loading the timing chain tensioner must be repeated. 16. Release the tensioner plunger, the plunger will press firmly against the back of the timing chain tensioner shoe. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Timing Chain Tensioner - Service Procedure > Page 2612 17. Remove J 36008-A from the camshaft sprockets. See Figure 6. Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. 18. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the J 36008-A Camshaft Sprocket Alignment Pins. The alignment pins will slide in easily if the engine is timed correctly. 19. Install the timing chain guides. See Figure 6. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2613 Timing Chain: Description and Operation An inverted tooth chain is used. A hydraulic tensioner and three guides control chain motion. The crankshaft and camshaft sprockets are powdered metal. The coolant pump sprocket, which acts as the timing chain idler sprocket, is steel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine Timing Chain: Service and Repair Interference Engine GM does not specify if this engine is an interference engine or not. To be safe, always observe the following precautions. If cylinder head is installed on the cylinder block: - DO NOT turn the crankshaft or camshaft if the timing belt/chain is not installed or if the camshaft timing has not been confirmed to be correct. - DO NOT rotate engine backwards. - If a broken or "jumped" timing belt/chain is suspected, DO NOT use the starter to crank the engine. - If a "catch" is felt when rotating the engine by hand, DO NOT attempt force the engine to rotate past the "catch". If cylinder head is removed (overhead cam engines): - Do not set cylinder head on a flat surface with combustion chamber down. When re-installing a cylinder head: - Confirm that the crankshaft AND camshaft gears align with their respective timing marks or confirm that all shafts are set to TDC for cylinder # 1 BEFORE placing the cylinder head onto the cylinder block. If the timing chain/belt has broken of "jumped time" with the engine running, always check for bent valves by pressurizing each cylinder with air with it's valves in the closed position. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2616 Timing Chain: Service and Repair Timing Chain and Sprocket Installation Installation NOTE: GM does not provide timing marks, or information to perform timing chain service without the special tools shown in this procedure. Tools Required: - J36800 Camshaft Sprocket Timing Alignment Pin - J39579 Camshaft Sprocket Wrench CAUTION: Failure to follow this procedure could result in severe engine damage. 1. Install the intake camshaft sprocket onto the camshaft with the marked surface showing. NOTICE: Use Adhesive/Sealant Compound GM P/N 12345493 or equivalent on the camshaft sprocket bolt. 2. Install the intake camshaft sprocket retaining bolt and washer. Tighten the bolt to 70 Nm ( 52 ft. lbs. ) while holding the sprocket with the camshaft sprocket wrench. NOTICE: DUE TO A PRODUCTION CHANGE, STEPS 3 THROUGH 21 HAVE BEEN REVISED. REFER TO "Updated Timing Chain Tensioner Installation" TO USE THE UPDATED PROCEDURE. STEPS 3 THROUGH 20 HAVE BEEN LEFT HERE FOR REFERENCE AND IMAGES. See: With 2 Piece Tensioner (TSB 67-61-22A)/Updated Timing Chain Tensioner/Installation 3. Install the camshaft sprocket timing alignment pin through the holes in the camshaft sprockets into the holes in the timing chain housing in order to position the camshaft for correct timing. 4. If the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins, use the following procedure: a. The crankshaft must be rotated 90 degrees clockwise off of the TDC in order to give the valves adequate clearance to open. b. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to the top dead center. WARNING: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. NOTE: The side of the timing chain that was marked during removal must be showing when the chain is installed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2617 5. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket. 6. Set the camshaft sprockets at the timed position and use the following procedure in order to install the timing chain: a. Remove the alignment dowel pin from the intake camshaft. b. Use the camshaft sprocket wrench in order to rotate the intake camshaft sprocket counter clockwise enough to slide the timing chain over the intake camshaft sprocket. c. Release the camshaft sprocket wrench. The length of the chain between the two camshaft sprockets will tighten. d. If properly timed the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 7. Leave the alignment dowel pins installed. 8. Raise and support the vehicle. 9. With the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and the recheck marks. 10. In order to reload the timing chain tensioner assembly to its zero position, form a keeper from a piece of heavy gauge wire. 11. Apply a slight force on the tensioner blade in order to compress the plunger. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2618 12. Insert a small screwdriver into the reset access hole, and pry the ratchet pawl away from the ratchet teeth while forcing the plunger completely in the hole. 13. Install the keeper between the access hole and the blade. 14. Install the tensioner assembly to the chain housing. Recheck the plunger assembly installation, it is correctly installed when the long end is toward the crankshaft. 15. Install the timing chain tensioner bolts. Tighten the bolts to 10 Nm ( 89 inch lbs. ). 16. Lower the vehicle enough to reach and remove the alignment dowel pins. 17. Rotate the crankshaft clockwise (normal rotation) two full rotations. 18. Align the crankshaft keyway with the mark on the cylinder block and reinstall alignment dowel pins. 19. Alignment dowel pins will slide in easily if the engine is timed correctly. 21. Install the timing chain guides. 22. Install the engine front cover. 23. Connect the negative battery cable. Removal Removal NOTE: GM does not provide timing marks, or information to perform timing chain service without the special tools shown in this procedure. Tools Required, or equivalent: J 36800 Camshaft Sprocket Timing Alignment Pin J 39579 Camshaft Sprocket Wrench NOTE: Before removing the timing chain, read the entire procedure. The timing chain and the crankshaft sprocket must be marked in order to insure reassembly with the same side facing out at the time of reassembly. CAUTION: The timing chain is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2619 Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. 1. Disconnect the negative battery cable. 2. Remove the engine front cover. 3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes line up with the holes in the timing chain housing. 4. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the "Timed" position. 5. Remove the timing chain guides. 6. Raise and support the vehicle. 7. Ensure that all of the slack in the timing chain is above the tensioner assembly. 8. Remove the timing chain tensioner. Refer to updated procedures. See: With 2 Piece Tensioner (TSB 67-61-22A)/Updated Timing Chain Tensioner/Removal 9. The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward. CAUTION: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur. 10. If difficulty is encountered in removing the timing chain tensioner shoe, use the following procedure in order to remove the intake camshaft sprocket. a. Lower the vehicle. b. Hold the intake camshaft sprocket with the camshaft sprocket wrench and remove the sprocket bolt and washer. c. Remove the washer from the bolt and rethread the bolt back into the camshaft by hand (the bolt provides a surface to push against). d. Remove the intake camshaft sprocket. Use a three-jaw puller in the three relief holes in the sprocket. 11. Remove the tensioner assembly retaining bolts and tensioner. CAUTION: The timing chain and the crankshaft sprocket must be marked prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2620 12. Mark the crankshaft sprocket and the timing chain outer surface. 13. Remove the timing chain. 14. Clean the old sealant off of the bolt with a wire brush. 15. Clean the threaded hole in the camshaft with a round nylon bristle brush. 16. Inspect the parts for wear and replace the parts as necessary. Some scoring of the timing chain shoe and the guides is normal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2621 Timing Chain: Service and Repair Timing Chain Caution Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing chain sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2622 Timing Chain: Service and Repair With 2 Piece Tensioner (TSB 67-61-22A) Precaution Bulletin No.: 67-61-22A Date: July, 1998 TIMING CHAIN TENSIONER SERVICE PROCEDURE This bulletin is being issued to update the service procedures for the timing chain tensioner on LD9 engines built after September 29, 1996. These engines have a new two-piece timing chain tensioner. IMPORTANT: The new two-piece timing chain tensioner is not interchangeable with the previous version. Do not attempt to replace the one-piece timing chain tensioner with the two piece design. NOTICE: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing chain sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. Removal This article has been updated with bulletin No. 67-61-22A. TIMING CHAIN, SPROCKETS, AND TENSIONER WITH 2 PIECE TENSIONER REMOVAL IMPORTANT: Read the entire procedure before removing the timing chain. 1. Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. Ensure that this is done in order to prevent noise and increased wear on the chain. 2. Remove the timing chain guides. See Figure 1. 3. Remove the timing chain tensioner block and tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2623 4. Remove the timing chain tensioner shoe from the stud. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud. See Figure 2. 5. Remove the timing chain. See Figure 3. 6. Inspect the parts for wear, replace them as required. 7. Replace the timing chain shoe or the guides if the scoring exceeds 1.12 mm (0.045 in.). 8. Remove the timing chain tensioner plunger from the tensioner body. When the timing chain tensioner body was removed from the housing, the plunger should have extended to full length exposing the drain holes. If the plunger did not extend, replace the tensioner assembly. 9. Place the tensioner plunger on its side on a shop rag to allow the oil to drain from the inside of the tensioner. Installation This article has been updated with bulletin No. 67-61-22A. TIMING CHAIN, SPROCKETS, AND TENSIONER WITH 2 PIECE TENSIONER INSTALLATION TOOLS REQUIRED * J 39579 Camshaft Sprocket Wrench * J 36008-A Camshaft Sprocket Alignment Pins IMPORTANT: Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil-seal-to-crankshaft alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2624 1. Install J 36008-A through holes in the camshaft sprockets and into holes in the timing chain housing. This will position the camshaft for correct timing. See Figure 4. 2. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn to install the alignment dowel pins: NOTICE: Failure to follow this procedure could result in severe engine damage. a. The crankshaft must be rotated 90 clockwise off of TDC to give the valves adequate clearance to open. b. Once the camshafts are in position and the J 36008-A Camshaft Sprocket Alignment Pins are installed, rotate the crankshaft counter-clockwise back to TDC. NOTICE: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. IMPORTANT: The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. 3. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 4. Remove the J 36008-A Camshaft Sprocket Alignment Pin from the intake camshaft. Use J 39579 in order to rotate the intake camshaft sprocket counter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. 5. Release J 39579. The length of the chain between the two camshaft sprockets will tighten. 6. If properly timed, the J 36008-A Camshaft Sprocket Alignment Pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 7. Leave the alignment dowel pins installed. 8. The keyway on the crankshaft and the mark on the cylinder block should be aligned, with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward; remove the slack and recheck the marks. See Figure 4. 9. Use the following steps in order to reload the tensioner assembly to its zero position: a. Assemble the tensioner plunger and the tensioner body. b. With the tensioner plunger fully extended, turn the tensioner and tensioner body upside down on a bench or other flat surface. A metal workbench is best for this. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2625 c. With the plunger face against the workbench, press firmly on the bottom of the tensioner body, compress the tensioner plunger until it is seated flush in the tensioner. See Figure 5. 10. Install the tensioner body and plunger to the chain housing. 11. Install the timing chain tensioner shoe on the stud. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. 12. Tighten the timing chain tensioner body bolts. Do not over-tighten. TIGHTEN Bolts to 10 Nm (89 lb in.) 13. Release the timing chain tensioner plunger. Press down until the plunger releases against the back of the timing chain tensioner shoe. NOTICE: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started. 14. Using a flat-blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of timing chain tensioner plunger. 15. Depress the timing chain tensioner plunger until it is bottomed out in the bore of the timing chain tensioner. If the timing chain tensioner cannot be depressed, it is not properly loaded and the procedure for loading the timing chain tensioner must be repeated. 16. Release the tensioner plunger, the plunger will press firmly against the back of the timing chain tensioner shoe. 17. Remove J 36008-A from the camshaft sprockets. See Figure 6. NOTICE: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2626 time of reassembly. 18. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the J 36008-A Camshaft Sprocket Alignment Pins. The alignment pins will slide in easily if the engine is timed correctly. 19. Install the timing chain guides. See Figure 6. Removal Important: Read the entire procedure before removing the timing chain. 1. Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. Ensure that this is done in order to prevent noise and increased wear on the chain. 2. Remove the timing chain guides. See Figure 1. 3. Remove the timing chain tensioner block and tensioner. 4. Remove the timing chain tensioner shoe from the stud. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud. See Figure 2. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2627 5. Remove the timing chain. See Figure 3. 6. Inspect the parts for wear, replace them as required. 7. Replace the timing chain shoe or the guides if the scoring exceeds 1.12 mm (0.045 in.). 8. Remove the timing chain tensioner plunger from the tensioner body. When the timing chain tensioner body was removed from the housing, the plunger should have extended to full length exposing the drain holes. If the plunger did not extend, replace the tensioner assembly. 9. Place the tensioner plunger on its side on a shop rag to allow the oil to drain from the inside of the tensioner. Installation Tools Required J 39579 Camshaft Sprocket Wrench J 36008-A Camshaft Sprocket Alignment Pins Important: Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil-seal-to-crankshaft alignment. 1. Install J 36008-A through holes in the camshaft sprockets and into holes in the timing chain housing. This will position the camshaft for correct timing. See Figure 4. 2. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn to install the alignment dowel pins: Notice: Failure to follow this procedure could result in severe engine damage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2628 a. The crankshaft must be rotated 90 clockwise off of TDC to give the valves adequate clearance to open. b. Once the camshafts are in position and the J 36008-A Camshaft Sprocket Alignment Pins are installed, rotate the crankshaft counter-clockwise back to TDC. Notice: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. Important: The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. 3. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 4. Remove the J 36008-A Camshaft Sprocket Alignment Pin from the intake camshaft. Use J 39579 in order to rotate the intake camshaft sprocket counter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. 5. Release J 39579. The length of the chain between the two camshaft sprockets will tighten. 6. If properly timed, the J 36008-A Camshaft Sprocket Alignment Pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 7. Leave the alignment dowel pins installed. 8. The keyway on the crankshaft and the mark on the cylinder block should be aligned, with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward; remove the slack and recheck the marks. See Figure 4. 9. Use the following steps in order to reload the tensioner assembly to its zero position: a. Assemble the tensioner plunger and the tensioner body. b. With the tensioner plunger fully extended, turn the tensioner and tensioner body upside down on a bench or other flat surface. A metal workbench is best for this. c. With the plunger face against the workbench, press firmly on the bottom of the tensioner body, compress the tensioner plunger until it is seated flush in the tensioner. See Figure 5. 10. Install the tensioner body and plunger to the chain housing. 11. Install the timing chain tensioner shoe on the stud. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. 12. Tighten the timing chain tensioner body bolts. Do not over-tighten. Tighten the bolts to 10 Nm (89 in. lb.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Interference Engine > Page 2629 13. Release the timing chain tensioner plunger. Notice: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started. 14. Using a flat-blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of timing chain tensioner plunger. 15. Depress the timing chain tensioner plunger until it is bottomed out in the bore of the timing chain tensioner. If the timing chain tensioner cannot be depressed, it is not properly loaded and the procedure for loading the timing chain tensioner must be repeated. 16. Release the tensioner plunger, the plunger will press firmly against the back of the timing chain tensioner shoe. 17. Remove J 36008-A from the camshaft sprockets. See Figure 6. Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. 18. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the J 36008-A Camshaft Sprocket Alignment Pins. The alignment pins will slide in easily if the engine is timed correctly. 19. Install the timing chain guides. See Figure 6. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure Timing Chain Tensioner: Technical Service Bulletins Engine - Timing Chain Tensioner Installation Procedure Bulletin No.: 00-06-01-010A Date: June 27, 2006 INFORMATION Subject: Timing Chain Tensioner Installation Procedure Models: 1996-1998 Buick Skylark 1996-2002 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am 1996-2002 Pontiac Sunfire 1996-2001 Toyota Cavalier with 2.4L Engine (VIN T - RPO LD9) Attention: This bulletin is being issued to draw attention to the proper timing chain tensioner reset and installation procedure. Warranty claims have been generated due to confusion about the proper procedure. The service manual procedure has been updated to provide clearer instructions. The proper procedure for resetting and installing the tensioner is included in the following text. Supercede: This bulletin is being revised to include additional model years and models. Please discard Corporate Bulletin Number 00-06-01-010 (Section 06 - Engine). Procedure Important: Use the following steps in order to reset the timing chain tensioner assembly to the zero position. 1. Reset the timing chain tensioner assembly. 1.1. Insert the tensioner plunger assembly into the tensioner housing. 1.2. With the tensioner plunger fully extended, turn the complete assembly upside down on a bench or other flat surface. 1.3. With the plunger face against the workbench, press firmly on the bottom of the tensioner housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2634 1.4. Compress the plunger until the plunger is seated flush in the tensioner. 2. Check the plunger to make sure that the plunger is out of the cylinder at the correct dimension. The correct dimension for the plunger to extend out of the cylinder is 1.7 mm (0.070 in) maximum. 3. Loosely install the tensioner assembly and bolts to the timing chain housing. 4. Install the timing chain tensioner shoe on the stud. 5. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. Note: Do not over tighten the bolts retaining the component or failure to the component may occur. 6. Tighten the timing chain tensioner bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2635 Note: If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started. 7. Release the timing chain tensioner plunger. 7.1. Using a flat blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of the timing chain tensioner plunger. Important: If the timing chain tensioner plunger cannot be depressed, the plunger is not properly reset and the procedure for resetting the timing chain tensioner should be repeated. 7.2. Depress the timing chain tensioner plunger until the plunger is bottomed out in the bore of the timing chain tensioner. 7.3. Release the tensioner plunger. The plunger should press firmly against the back of the timing chain tensioner shoe. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2636 Timing Chain Tensioner: Technical Service Bulletins Timing Chain Tensioner - Revised Installation Procedure Bulletin No.: 00-06-01-002 File In Section: 06 - Engine/Propulsion System Date: February, 2000 Subject: Revised Timing Chain, Sprockets, Tensioner Installation Procedure Models: 1998-1999 Chevrolet Malibu 1998-2000 Chevrolet Cavalier 1998 Oldsmobile Achieva 1999-2000 Oldsmobile Alero 1998-2000 Pontiac Grand Am, Sunfire with 2.4 L Engine (VIN T RPO LD9) This bulletin is being issued to revise the Timing Chain, Sprockets and Tensioner Installation Procedure. Please use the following to replace the existing information in the Engine Mechanical sub-section of the Engine Section in the 1998-2000 Service Manuals. Procedure 1. Install the camshaft sprockets. The sprockets are identical and interchangeable. 2. Clean the old sealer off of the bolts with a wire brush. 3. Clean the threaded hole in the camshaft with a nylon bristle brush. 4. Coat the camshaft bolts with Adhesive/Sealant Compound GM P/N 1234593 or equivalent. NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 5. Install the camshaft sprocket bolts and washers while holding the sprockets with J 39579. Tighten Tighten the bolts to 70 N.m (52 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2637 IMPORTANT: Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil seat to crankshaft alignment. 6. Install the J 36008-A through the holes in the camshaft sprockets and into the holes in the timing chain housing. This will position the camshaft for correct timing. 7. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins: 7.1. The crankshaft must be rotated 90 degrees clockwise off of TDC to give the valves adequate clearance to open. 7.2. Once the camshafts are in position and the dowels are installed, rotate the crankshaft counter clockwise back to TDC. NOTICE: Do NOT rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. IMPORTANT: The timing chain and crankshaft sprocket must be put in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. 8. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 9. Remove the alignment dowel pin from the intake camshaft. Use the J 39579 in order to rotate the intake camshaft sprocket counter clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. 10. Release the J 39579. The length of the chain between the two camshaft sprockets will tighten. 11. If properly timed, the intake camshaft alignment dowel pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2638 12. Leave the alignment dowel pins installed. 13. The keyway on the crankshaft and the mark on the cylinder block should be aligned with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward. Remove the slack and recheck the marks. IMPORTANT: Use the following steps in order to reset the timing chain tensioner assembly to the zero position: 14. Reset the timing chain tensioner assembly. 14.1. Insert the tensioner plunger assembly into the tensioner housing. 14.2. With the tensioner plunger fully extended, turn the complete assembly upside down on a bench or other flat surface. 14.3. With the plunger face against the workbench, press firmly on the bottom of the tensioner housing. 14.4. Compress the plunger until the plunger is seated flush in the tensioner. 15. Check the plunger to make sure that the plunger is out of the cylinder at the correct dimension. The correct dimension for the plunger to extend out of the cylinder is 1.7 mm (0.07 in) maximum. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2639 16. Loosely install the tensioner assembly and bolts to the timing chain housing. 17. Install the timing chain tensioner shoe on the stud. 18. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. 19. Tighten the timing chain tensioner bolts. Do not over tighten. Tighten Tighten the bolts to 10 Nm (89 lb in). NOTICE: If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started. 20. Release the timing chain tensioner plunger. 20.1. Using a flat blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of the timing chain tensioner plunger. IMPORTANT: If the timing chain tensioner plunger cannot be depressed, the plunger is not properly reset and the procedure for resetting the timing chain tensioner should be repeated. 20.2. Depress the timing chain tensioner plunger until the plunger is bottomed out in the bore of the timing chain tensioner. 20.3. Release the tensioner plunger. The plunger should press firmly against the back of the timing chain tensioner shoe. 21. Remove the J 36008-A from the camshaft sprockets. NOTICE: Beginning with the 1998 model year, the timing chain on the LD9 (VIN T) Twin Cam Engine is different from the chain found on earlier versions of Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2640 this engine, and is not to be replaced with a timing chain from earlier model year engines. The timing sprockets were also changed beginning in 1998, and the shape of the chain links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing out at the time of assembly. 22. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the alignment dowel pins. The alignment dowel pins will slide in easily if the engine is timed correctly. 23. Install the timing chain guides. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2641 Technical Service Bulletin # 67-61-22A Date: 980701 Timing Chain Tensioner - Service Procedure File In Section: 6 Engine Bulletin No.: 67-61-22A Date: July, 1998 SERVICE MANUAL UPDATE Subject: Section 6A - Engine Mechanical - Timing Chain Tensioner Service Procedure Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva 1997-98 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN T - RPO LD9) This bulletin is being revised to clarify the service procedure in regards to timing chain tensioner installation and to include the 1998 model year. Please discard Corporate Bulletin Number 67-61-22 (Section 6 - Engine). This bulletin is being issued to update the service procedures for the timing chain tensioner on LD9 engines built after September 29, 1996. These engines have a new two-piece timing chain tensioner. Important: The new two-piece timing chain tensioner is not interchangeable with the previous version. Do not attempt to replace the one-piece timing chain tensioner with the two piece design. Timing Chain, Sprockets, and Tensioner Removal Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing chain sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. Procedure Important: Read the entire procedure before removing the timing chain. 1. Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. Ensure that this is done in order to prevent noise and increased wear on the chain. 2. Remove the timing chain guides. See Figure 1. 3. Remove the timing chain tensioner block and tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2642 4. Remove the timing chain tensioner shoe from the stud. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud. See Figure 2. 5. Remove the timing chain. See Figure 3. 6. Inspect the parts for wear, replace them as required. 7. Replace the timing chain shoe or the guides if the scoring exceeds 1.12 mm (0.045 in.). 8. Remove the timing chain tensioner plunger from the tensioner body. When the timing chain tensioner body was removed from the housing, the plunger should have extended to full length exposing the drain holes. If the plunger did not extend, replace the tensioner assembly. 9. Place the tensioner plunger on its side on a shop rag to allow the oil to drain from the inside of the tensioner. Timing Chain, Sprockets, and Tensioner Installation Tools Required J 39579 Camshaft Sprocket Wrench J 36008-A Camshaft Sprocket Alignment Pins Important: Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil-seal-to-crankshaft alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2643 1. Install J 36008-A through holes in the camshaft sprockets and into holes in the timing chain housing. This will position the camshaft for correct timing. See Figure 4. 2. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn to install the alignment dowel pins: Notice: Failure to follow this procedure could result in severe engine damage. a. The crankshaft must be rotated 90 clockwise off of TDC to give the valves adequate clearance to open. b. Once the camshafts are in position and the J 36008-A Camshaft Sprocket Alignment Pins are installed, rotate the crankshaft counter-clockwise back to TDC. Notice: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. Important: The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. 3. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 4. Remove the J 36008-A Camshaft Sprocket Alignment Pin from the intake camshaft. Use J 39579 in order to rotate the intake camshaft sprocket counter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. 5. Release J 39579. The length of the chain between the two camshaft sprockets will tighten. 6. If properly timed, the J 36008-A Camshaft Sprocket Alignment Pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 7. Leave the alignment dowel pins installed. 8. The keyway on the crankshaft and the mark on the cylinder block should be aligned, with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward; remove the slack and recheck the marks. See Figure 4. 9. Use the following steps in order to reload the tensioner assembly to its zero position: a. Assemble the tensioner plunger and the tensioner body. b. With the tensioner plunger fully extended, turn the tensioner and tensioner body upside down on a bench or other flat surface. A metal workbench is best for this. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2644 c. With the plunger face against the workbench, press firmly on the bottom of the tensioner body, compress the tensioner plunger until it is seated flush in the tensioner. See Figure 5. 10. Install the tensioner body and plunger to the chain housing. 11. Install the timing chain tensioner shoe on the stud. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. 12. Tighten the timing chain tensioner body bolts. Do not over-tighten. Tighten Tighten the bolts to 10 N.m (89 lb in.) Refer to Fastener Notice in General Information. 13. Release the timing chain tensioner plunger. Notice: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started. 14. Using a flat-blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of timing chain tensioner plunger. 15. Depress the timing chain tensioner plunger until it is bottomed out in the bore of the timing chain tensioner. If the timing chain tensioner cannot be depressed, it is not properly loaded and the procedure for loading the timing chain tensioner must be repeated. 16. Release the tensioner plunger, the plunger will press firmly against the back of the timing chain tensioner shoe. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Engine - Timing Chain Tensioner Installation Procedure > Page 2645 17. Remove J 36008-A from the camshaft sprockets. See Figure 6. Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. 18. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the J 36008-A Camshaft Sprocket Alignment Pins. The alignment pins will slide in easily if the engine is timed correctly. 19. Install the timing chain guides. See Figure 6. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Page 2646 Timing Chain Tensioner: Specifications Timing Chain Tensioner to Housing and Block .................................................................................................................................... 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution Timing Chain Tensioner: Service and Repair Precaution Bulletin No.: 67-61-22A Date: July, 1998 TIMING CHAIN TENSIONER SERVICE PROCEDURE This bulletin is being issued to update the service procedures for the timing chain tensioner on LD9 engines built after September 29, 1996. These engines have a new two-piece timing chain tensioner. IMPORTANT: The new two-piece timing chain tensioner is not interchangeable with the previous version. Do not attempt to replace the one-piece timing chain tensioner with the two piece design. NOTICE: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing chain sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2649 Timing Chain Tensioner: Service and Repair Removal This article has been updated with bulletin No. 67-61-22A. TIMING CHAIN, SPROCKETS, AND TENSIONER WITH 2 PIECE TENSIONER REMOVAL IMPORTANT: Read the entire procedure before removing the timing chain. 1. Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. Ensure that this is done in order to prevent noise and increased wear on the chain. 2. Remove the timing chain guides. See Figure 1. 3. Remove the timing chain tensioner block and tensioner. 4. Remove the timing chain tensioner shoe from the stud. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud. See Figure 2. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2650 5. Remove the timing chain. See Figure 3. 6. Inspect the parts for wear, replace them as required. 7. Replace the timing chain shoe or the guides if the scoring exceeds 1.12 mm (0.045 in.). 8. Remove the timing chain tensioner plunger from the tensioner body. When the timing chain tensioner body was removed from the housing, the plunger should have extended to full length exposing the drain holes. If the plunger did not extend, replace the tensioner assembly. 9. Place the tensioner plunger on its side on a shop rag to allow the oil to drain from the inside of the tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2651 Timing Chain Tensioner: Service and Repair Installation This article has been updated with bulletin No. 67-61-22A. TIMING CHAIN, SPROCKETS, AND TENSIONER WITH 2 PIECE TENSIONER INSTALLATION TOOLS REQUIRED * J 39579 Camshaft Sprocket Wrench * J 36008-A Camshaft Sprocket Alignment Pins IMPORTANT: Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil-seal-to-crankshaft alignment. 1. Install J 36008-A through holes in the camshaft sprockets and into holes in the timing chain housing. This will position the camshaft for correct timing. See Figure 4. 2. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn to install the alignment dowel pins: NOTICE: Failure to follow this procedure could result in severe engine damage. a. The crankshaft must be rotated 90 clockwise off of TDC to give the valves adequate clearance to open. b. Once the camshafts are in position and the J 36008-A Camshaft Sprocket Alignment Pins are installed, rotate the crankshaft counter-clockwise back to TDC. NOTICE: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. IMPORTANT: The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. 3. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 4. Remove the J 36008-A Camshaft Sprocket Alignment Pin from the intake camshaft. Use J 39579 in order to rotate the intake camshaft sprocket counter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. 5. Release J 39579. The length of the chain between the two camshaft sprockets will tighten. 6. If properly timed, the J 36008-A Camshaft Sprocket Alignment Pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 7. Leave the alignment dowel pins installed. 8. The keyway on the crankshaft and the mark on the cylinder block should be aligned, with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward; remove the slack and recheck the marks. See Figure 4. 9. Use the following steps in order to reload the tensioner assembly to its zero position: a. Assemble the tensioner plunger and the tensioner body. b. With the tensioner plunger fully extended, turn the tensioner and tensioner body upside down on a bench or other flat surface. A metal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2652 workbench is best for this. c. With the plunger face against the workbench, press firmly on the bottom of the tensioner body, compress the tensioner plunger until it is seated flush in the tensioner. See Figure 5. 10. Install the tensioner body and plunger to the chain housing. 11. Install the timing chain tensioner shoe on the stud. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. 12. Tighten the timing chain tensioner body bolts. Do not over-tighten. TIGHTEN Bolts to 10 Nm (89 lb in.) 13. Release the timing chain tensioner plunger. Press down until the plunger releases against the back of the timing chain tensioner shoe. NOTICE: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started. 14. Using a flat-blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of timing chain tensioner plunger. 15. Depress the timing chain tensioner plunger until it is bottomed out in the bore of the timing chain tensioner. If the timing chain tensioner cannot be depressed, it is not properly loaded and the procedure for loading the timing chain tensioner must be repeated. 16. Release the tensioner plunger, the plunger will press firmly against the back of the timing chain tensioner shoe. 17. Remove J 36008-A from the camshaft sprockets. See Figure 6. NOTICE: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2653 timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. 18. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the J 36008-A Camshaft Sprocket Alignment Pins. The alignment pins will slide in easily if the engine is timed correctly. 19. Install the timing chain guides. See Figure 6. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2654 Timing Chain Tensioner: Service and Repair Updated Timing Chain Tensioner Installation Tools Required J 39579 Camshaft Sprocket Wrench J 36008-A Camshaft Sprocket Alignment Pins Important: Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil-seal-to-crankshaft alignment. 1. Install J 36008-A through holes in the camshaft sprockets and into holes in the timing chain housing. This will position the camshaft for correct timing. See Figure 4. 2. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn to install the alignment dowel pins: Notice: Failure to follow this procedure could result in severe engine damage. a. The crankshaft must be rotated 90 clockwise off of TDC to give the valves adequate clearance to open. b. Once the camshafts are in position and the J 36008-A Camshaft Sprocket Alignment Pins are installed, rotate the crankshaft counter-clockwise back to TDC. Notice: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. Important: The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed. 3. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. 4. Remove the J 36008-A Camshaft Sprocket Alignment Pin from the intake camshaft. Use J 39579 in order to rotate the intake camshaft sprocket counter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. 5. Release J 39579. The length of the chain between the two camshaft sprockets will tighten. 6. If properly timed, the J 36008-A Camshaft Sprocket Alignment Pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 7. Leave the alignment dowel pins installed. 8. The keyway on the crankshaft and the mark on the cylinder block should be aligned, with the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward; remove the slack and recheck the marks. See Figure 4. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2655 9. Use the following steps in order to reload the tensioner assembly to its zero position: a. Assemble the tensioner plunger and the tensioner body. b. With the tensioner plunger fully extended, turn the tensioner and tensioner body upside down on a bench or other flat surface. A metal workbench is best for this. c. With the plunger face against the workbench, press firmly on the bottom of the tensioner body, compress the tensioner plunger until it is seated flush in the tensioner. See Figure 5. 10. Install the tensioner body and plunger to the chain housing. 11. Install the timing chain tensioner shoe on the stud. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. 12. Tighten the timing chain tensioner body bolts. Do not over-tighten. Tighten the bolts to 10 Nm (89 in. lb.) 13. Release the timing chain tensioner plunger. Notice: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started. 14. Using a flat-blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of timing chain tensioner plunger. 15. Depress the timing chain tensioner plunger until it is bottomed out in the bore of the timing chain tensioner. If the timing chain tensioner cannot be depressed, it is not properly loaded and the procedure for loading the timing chain tensioner must be repeated. 16. Release the tensioner plunger, the plunger will press firmly against the back of the timing chain tensioner shoe. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2656 17. Remove J 36008-A from the camshaft sprockets. See Figure 6. Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled with the same side facing out at the time of reassembly. 18. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the J 36008-A Camshaft Sprocket Alignment Pins. The alignment pins will slide in easily if the engine is timed correctly. 19. Install the timing chain guides. See Figure 6. Removal Important: Read the entire procedure before removing the timing chain. 1. Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. Ensure that this is done in order to prevent noise and increased wear on the chain. 2. Remove the timing chain guides. See Figure 1. 3. Remove the timing chain tensioner block and tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Precaution > Page 2657 4. Remove the timing chain tensioner shoe from the stud. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud. See Figure 2. 5. Remove the timing chain. See Figure 3. 6. Inspect the parts for wear, replace them as required. 7. Replace the timing chain shoe or the guides if the scoring exceeds 1.12 mm (0.045 in.). 8. Remove the timing chain tensioner plunger from the tensioner body. When the timing chain tensioner body was removed from the housing, the plunger should have extended to full length exposing the drain holes. If the plunger did not extend, replace the tensioner assembly. 9. Place the tensioner plunger on its side on a shop rag to allow the oil to drain from the inside of the tensioner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Specifications Timing Chain Housing: Specifications Timing Chain Housing to the Camshaft Housings .................................................................................................................................... 26 Nm (19 ft. lbs.) Timing Chain Housing to the Block Bolts/Studs ...................................................................................................................................... 29 Nm (21 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Specifications > Page 2661 Timing Chain Housing: Description and Operation The timing chain housing is die cast aluminum. The housing assembly includes the oil fill location. The timing chain cover is laminated stamped steel and retains the crankshaft front seal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Service and Repair > Engine Front Cover Timing Chain Housing: Service and Repair Engine Front Cover Removal ^ Tools Required, or equivalent: J 28467-360 Engine Support Fixture J 28467-400 Engine Lift Hook 1. Disconnect the negative battery cable. 2. Drain and recover the coolant. See Cooling System. 3. Remove the coolant surge tank. See Cooling System. 4. Remove the drive belt. 5. Install the engine support fixture and the engine lift hook onto the generator stud-ended bolt. 6. Remove the upper fasteners from the front cover. 7. Remove the engine mount assembly. 8. Remove the engine mounting bracket adapter. 9. Raise and support the vehicle. 10. Remove the right front wheel and the tire assembly. 11. Remove the right splash shield. 12. Remove the crankshaft pulley. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Service and Repair > Engine Front Cover > Page 2664 13. Remove the lower front cover fasteners. 14. Lower the vehicle. 15. Remove the front cover and the gasket. 16. Inspect the front cover gasket. Replace the gasket if it is damaged. Installation ^ Tools Required - J 36660 Torque Angle Meter, or equivalent. 1. Install the front cover gasket. The gasket is reusable and does not require sealer. 2. Install the upper front cover fasteners. Tighten the fasteners to 13 Nm (115 inch lbs.). 3. Raise and suitably support the vehicle. 4. Install the remaining front cover fasteners. Tighten the fasteners to 13 Nm (115 inch lbs.). 5. Lubricate the front oil seal and the sealing surface of the crankshaft balancer with chassis grease GM P/N 1051344 or equivalent. 6. Install the crankshaft balancer. 7. Install the right splash shield. 8. Install the right front wheel and tire assembly. 9. Lower the vehicle. 10. Install the engine mounting bracket adapter. CAUTION: This bolt is designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged. NOTE: These bolts must be replaced with new bolts anytime they are removed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Service and Repair > Engine Front Cover > Page 2665 11. Install the engine mounting bracket adapter bolts. Tighten the bolts to 60 Nm (44 ft. lbs.) + 60 degrees. Use the torque angle meter. 12. Install the engine mount assembly. 13. Remove the engine support fixture and the engine lift hook. 14. Install the drive belt. 15. Install the coolant surge tank. See Cooling System. 16. Add coolant. See Cooling System. 17. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Service and Repair > Engine Front Cover > Page 2666 Timing Chain Housing: Service and Repair Timing Chain Housing Replacement Removal ^ Tools Required, or equivalent: J 24420-B Crankshaft Balancer Puller J 28467-360 Engine Support J 38122 Crankshaft Balancer Holder NOTE: The timing chain housing to cylinder block and the camshaft housing gaskets can be replaced without removing the timing chain housing from the vehicle. Removal of the timing chain housing is only required when additional service is being performed on the timing chain housing. 1. Disconnect the negative battery cable. 2. Remove the engine front cover. 3. Raise and support the vehicle. 4. Disconnect the heater hose from the thermostat housing in order to drain the cylinder block completely. NOTE: The timing chain must be marked prior to removal. If the chain is installed with the wear pattern in the opposite direction, noise and increased wear may occur. 5. Remove the timing chain tensioner. 6. Remove the timing chain. 7. Remove the coolant pump assembly to the timing chain housing nuts. See Cooling System. 8. Remove the timing chain housing to the block fasteners. 9. Remove the four oil pan to front cover bolts. 10. Remove the lowest front cover retaining stud from the timing chain housing. This stud will catch on the body if it is not removed. 11. Lower the vehicle. 12. Remove the camshaft sprocket retaining bolts and the washers while holding the sprockets with the crankshaft balancer holder. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Service and Repair > Engine Front Cover > Page 2667 13. Remove the camshaft sprockets. The camshaft sprockets are identical and interchangeable. 14. Remove the chain housing to the camshaft housing bolts. 15. Remove the timing chain housing and the gaskets. It may be necessary to raise the engine slightly using an engine support. 16. Inspect the oil pan gasket silicone bead for the following conditions: ^ Cuts or nicks. ^ Deformation. ^ Separation from the aluminum carrier. 17. If any of the conditions exist, replace the pan gasket. NOTE: Use only enough sealant to restore the silicone bead to its original dimension. Excess application of sealant may cause part misalignment and oil leaks. 18. Inspect the silicone bead across the top of the aluminum carrier at the oil pan, in the cylinder block, and to the timing chain housing three way joint. Repair a damaged bead using the silicone rubber sealant GM P/N 12345739 or the equivalent. Installation 1. Prior to installing the timing chain housing, ensure that the alignment dowel pins are in the cylinder block and the timing chain housing. The dowel pins ensure proper chain housing and the front cover location for correct front oil seal-to-crankshaft alignment. 2. Install the timing chain housing and the new gaskets. Gasket sealer is unnecessary. NOTE: Hand tighten all chain housing bolts before tightening to specifications. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Service and Repair > Engine Front Cover > Page 2668 3. Install the chain housing to the camshaft housing bolts and hand tighten. 4. Raise and support the vehicle. 5. Install the timing chain housing block fasteners and hand tighten. 6. Install the oil pan to the timing chain housing bolts and hand tighten. 7. Tighten the timing chain housing block fasteners. ^ (1) (M8 X 1.25 X 25) 26 Nm (19 ft. lbs.). ^ (2) (M8 X 1.55 X 55) 50 Nm (37 ft. lbs.). ^ (3) (M10 X 1.25 X 35) 29 Nm (21 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Housing <--> [Timing Cover] > Component Information > Service and Repair > Engine Front Cover > Page 2669 8. Tighten the oil pan to the timing chain housing bolts. ^ (1) (M8 X 1.25 X 80) 24 Nm (18 ft. lbs.). ^ (2) (M8 X 1.24 X 22) 24 Nm (18 inch lbs.). ^ (3) (M6 X 1.00 X 25) 12 Nm (106 ft. lbs.). ^ (4) 26 Nm (19 ft. lbs.). 9. Install the lowest front cover retaining stud into the timing chain housing. 10. Install the coolant pump to the timing chain housing and the timing chain housing nuts. Tighten the timing chain housing nuts to 26 Nm (19 ft. lbs.). 11. Lower the vehicle. 12. Tighten the timing chain housing to the camshaft housing bolts. ^ (1) (M8 X 1.25 X 25) 26 Nm (19 ft. lbs.). ^ (2) (M10 X 1.55 X 55) 50 Nm (37 ft. lbs.). ^ (3) (M8 X 1.25 X 35) 29 Nm (21 ft. lbs.). 13. Install the camshaft sprockets. The camshaft sprockets are identical and interchangeable. 14. Install the camshaft sprocket bolts and the washers. 15. Tighten the camshaft sprocket bolts and the washers while holding the sprocket with the crankshaft balancer holder. Tighten the camshaft sprocket bolts to 70 Nm (52 ft. lbs.). 16. Use the Adhesive/Sealant Compound GM P/N 12345493 or the equivalent on the camshaft sprocket bolts. 17. Clean the old sealant off of the bolt with a wire brush. 18. Clean the threaded hole in the camshaft with a round nylon brush. 19. Clean the threaded hole in the camshaft with a round nylon brush. NOTE: The side of the timing chain that was marked during the removal must be showing when the chain is installed. 20. Install the timing chain and the tensioner. 21. Install the front cover and the gaskets. 22. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 2675 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2676 Fuel Pressure: Service Precautions CAUTION: The following procedures and conditions MUST be followed or parts and system damage could result. 1. Do not operate the fuel pump without fuel in the lines. 2. Torque all screw couple fittings and fasteners to the specified torque. 3. If a fastener needs to be replaced, use the correct part number fastener or a fastener of equal size and strength (or stronger) for that application. 4. Always use a backup wrench when loosening or tighting a screw couple fitting. 5. On fuel injected models do not depress the accelerator pedal while trying to start the car. 6. Handle all fuel injection related parts with care as they may easily be damaged. 7. Always use new gaskets or O-rings when installing fuel lines or injectors. 8. Lightly lubricate O-rings and flare connections with gasoline. Do NOT use engine oil, gear lubricant or brake fluid. 9. Take care not to nick or scratch any nylon fuel lines. If damaged, they must be replaced. 10. Always cover nylon fuel lines with a wet towel before using a torch near them. Never expose the vehicle to temperatures higher than 115°C (239° F) for more than one hour, or more than 90°C (194°F) for any extended period. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2677 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2678 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2679 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2680 Diagnostic Chart Gauge Hookups CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn the in-tank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION Number(s) below refer to the step number(s) on the Diagnostic Table. 2. To relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition switch is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gage should be 284-325 kPa (41-47 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that can not maintain a constant fuel pressure has a leak in one or more of the following areas: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2681 ^ The fuel pump check valve. ^ The fuel pump flex pipe. ^ The valve or valve seat within the fuel pressure regulator. ^ The fuel injector(s). 4. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector width will increase. NOTE: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. This can cause false indications by the scan tool. 7. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the Engine OFF. 11. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 12. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a faulty fuel pressure regulator. 15. A lean condition may result from the fuel pressure being below 284 kPa (41 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold), hesitation, poor driveability, lack of power, surging, and misfiring. 16. Restricting the fuel return pipe causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gage outlet hose is pinched. 22. Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. 24. The fuel pressure regulator filter screen is designed to trap any contaminants introduced during engine assembly. If the fuel pressure regulator screen is dirty, it can be removed with a small pick and discarded without potential harm to the fuel pressure regulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 2685 Air/Fuel Mixture: Adjustments The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: Customer Interest Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 2694 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: All Technical Service Bulletins Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 2700 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2701 Idle Speed: By Symptom Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2702 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2703 Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2704 For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2705 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2706 Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2707 Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2708 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Specifications Air Cleaner Fresh Air Duct/Hose: Specifications Resonator Upper Attaching Bolt .......................................................................................................... ....................................................... 7 Nm (61 lb. in.) Headlamp Assembly Retaining Screws ....................................................................................................................................................... 7 Nm (61 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct Air Cleaner Fresh Air Duct/Hose: Service and Repair Front Air Duct Removal Procedure 1. Remove the air cleaner outlet splash shield. 2. Remove the LH headlamp assembly retaining screws. 3. Remove the LH headlamp assembly. 4. Disconnect the LH headlamp electrical connector(s). 5. Remove the front air cleaner outlet duct upper push in retainer. 6. Remove the resonator front push in retainer. 7. Raise the vehicle. 8. Remove the LF tire and wheel. 9. Remove the LF wheel house panel. 10. Remove the front air cleaner outlet duct lower retaining screw. 11. Remove the front air cleaner outlet duct through headlamp assembly opening. 12. Remove the resonator rear push in retainer and upper attaching bolt. 13. Remove the resonator assembly through wheel house opening. Installation Procedure 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push in retainer and the upper attaching bolt. Tighten the Resonator upper attaching bolt to 7 Nm (61 lb. in.). 3. Install the front air cleaner outlet duct through the headlamp assembly opening. 4. Install the front air cleaner outlet duct lower retaining screw. 5. Install the LF wheel house panel. 6. Install the LF tire and wheel. 7. Lower the vehicle. 8. Install the resonator front push in retainer. 9. Install the front air cleaner outlet duct upper push in retainer. 10. Install the LH headlamp electrical connector(s). 11. Install the LH headlamp assembly retaining screws. Tighten the headlamp assembly retaining screws to 7 Nm (61 lb. in.). 12. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct > Page 2715 Air Cleaner Fresh Air Duct/Hose: Service and Repair Fresh Air Hose Removal Procedure 1. Remove the air cleaner outlet resonator mounting screws. 2. Disconnect the air cleaner outlet resonator clamp at throttle body. 3. Remove the air cleaner outlet duct from air cleaner outlet resonator and air cleaner assembly. 4. Disconnect the crankcase vent hose from the air cleaner outlet duct. 5. Remove the air cleaner outlet resonator. Installation Procedure Important: Be sure that the air cleaner outlet resonator seals to the throttle body. 1. Install the air cleaner outlet resonator to the throttle body. 2. Connect the crankcase vent hose to the air cleaner outlet duct. 3. Install the air cleaner outlet resonator mounting screws. Tighten: ^ Air cleaner outlet resonator mounting screws to 5-7 Nm 60-84 lb. in.). ^ Air cleaner outlet resonator clamp to 4-5 Nm 35-44 lb in). 4. Install the air cleaner outlet duct to the air cleaner outlet resonator and the air cleaner assembly. Tighten Air cleaner outlet duct clamps to 45 Nm (35-44 lb. in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2724 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2730 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2731 Air Filter Element: Specifications Air Cleaner Cover Screws ................................................................................................................... ........................................................ 3 Nm (26 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2732 Air Filter Element: Service and Repair Air Filter Removal Procedure 1. Remove the upper air cleaner screws. 2. Remove the air cleaner cover. 3. Remove the air cleaner filter from lower air cleaner housing. 4. Inspect the air cleaner filter for dust, dirt, and water. 5. Replace if required. Installation Procedure 1. Install the air cleaner filter into the lower air cleaner housing. 2. Install the air cleaner cover to air cleaner housing. 3. Install the air cleaner screws. Tighten the air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition - Revised Spark Plug Gap Spark Plug: Technical Service Bulletins Ignition - Revised Spark Plug Gap File In Section: 6E - Engine Fuel & Emission Bulletin No.: 77-65-11A Date: May, 1997 INFORMATION Subject: Production Spark Plug Gap Change Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN T - RPO LD9) This bulletin is being revised to add Chevrolet Malibu to models. Please discard Corporate Bulletin Number 77-65-11 (Section 6E - Engine Fuel & Emission). A change in spark plug gap has been made to reduce spark plug fouling during repeated low speed operation of these vehicles at assembly plants, rail heads and dealer/retailer unloading points. The electrode gap of the production spark plugs has been reduced from 1.52 mm (0.060 in) to 1.27 mm (0.050 in). If a spark plug is removed to perform a service procedure and the gap is found to be 1.52 mm (0.060 in) and the spark plugs are functioning normally, do not change the spark plugs. Original equipment spark plugs will have the production part number imprinted on the ceramic insulator. The 1.52 mm (0.060 in) electrode gap spark plug will have a production part number of 25164044 and the 1.27 mm (0.050 in) electrode gap spark plug will have a production part number of 25312636. The service spark plug part number for all 1997 LD9 engines is 25164048 with an electrode gap of 1.27 mm (0.050 in). Important: Do not mix spark plugs with different electrode gaps on the same engine. If it becomes necessary to change a spark plug in any of these vehicles equipped with spark plugs that have a 1.52 mm (0.060 in) gap, replace all four spark plugs with GM Part Number 25164048 with the electrode gap set at 1.27 mm (0.050 in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2755 Spark Plug: Specifications Spark Plug Torque 13 lb. ft. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2756 Spark Plug: Application and ID Spark Plug Identification Chart Spark Plugs: GM Part # 24161677 A-C Type 41-928 Gapped @ 1.52mm (0.060 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2757 Spark Plug: Description and Operation NOTE: This engine has aluminum cylinder heads. Allow the engine to cool before removing spark plugs, or the spark plug threads in the cylinder head may be damaged. - This engine uses tapered seat resistor type spark plugs without gaskets. Always replace plugs with the same spark plug as listed. DESCRIPTION Normal service is assumed to be a mixture of idling, slow speed, and high speed driving. Occasional or intermittent highway driving is needed for good spark plug performance because it gives increased combustion heat that bums away any excess deposits of carbon or oxides that have built up from frequent idling or continual stop-and-go driving. Spark plugs are protected by an insulating boot made of special heat-resistant material which covers the spark plug terminal and extends downward over a portion of the plug insulator. These boots prevent flash-over which causes engine mis-firing. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of a high-tension field, and has no effect on ignition performance. Usually it can be detected only in darkness. This discharge may repel dust particles, leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Spark plugs must operate within certain temperature limits if they are to provide the performance and service life expected. The spark plug selected for an engine is based on the normal service which the engine was designed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2758 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2759 Spark Plug: Service and Repair CAUTION: To avoid engine damage, do not remove spark plugs when engine is warm. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Electronic ignition module assembly 4 bolts and connector. 3. Remove by pulling straight up on housing. 4. Use tool J 36011 or equivalent to remove connector assembly(s) if stuck to the spark plugs. - Use tool by first twisting then pulling up on the connector assembly. 5. Remove debris from area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. INSTALL OR CONNECT 1. Adjust spark plug gap to 1.52 mm (0.060 inch) using a round wire type spark plug gap gage. While gapping plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start spark plugs into the cylinder head. Tighten Spark plugs to 18 Nm (13 lbs. ft.). 3. Reinstall onto the module assembly any spark plug boot connector assembly that stuck to a spark plug. - Check to be sure spring terminal is inside boot. - Reapply dielectric lubricant to insulator boot. 4. Locate module assembly over spark plugs and push straight down. 5. Clean any loose lubricant that is present on the module assembly to cam housing bolts. 6. Apply threadlocker onto the module assembly to cam housing bolts. CAUTION: Hand start the module assembly to cam housing bolts. Tighten Bolts to 22 Nm (16 lbs. ft.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2760 7. Electrical connector. 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Intake Valve Cold Valve Lash ................................................................................................................................... 0.13 - 0.17 mm (0.005 - 0.007 inches) Exhaust Valve Cold Valve Leash .............................................................................................................................. 0.13 - 0.17 mm (0.005 - 0.007 inches) Intake Valve Hot Valve Leash ................................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Exhaust Valve Hot Valve Leash ............................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 01-06-02-012 > Dec > 01 > Water Pump - Coolant Weepage Water Pump: Customer Interest Water Pump - Coolant Weepage File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-02-012 Date: December, 2001 TECHNICAL Subject: Water Pump Weep (Install Coolant Collector) Models: 1996-1998 Buick Skylark 1996-2002 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am 1996-2002 Pontiac Sunfire with 2.4L Engine (VIN T - RPO LD9) Condition Some owners may comment on leakage of a few drops of coolant after parking their vehicle. A technician may notice that the water pump may show a staining around the weep hole. Cause The occasional drop of coolant and the staining may be the evidence of normal coolant weepage. The weep hole prevents normal coolant weepage from accumulating around the bearing seal. For more information on this normal condition, refer to Corporate Bulletin Number 00-06-02-009. Correction Replacing the water pump for this normal weepage is likely to result in a repeat of the customer concern. To address customer concerns and promote customer satisfaction, a coolant collector has been developed to trap and absorb normal weepage of the pump. The coolant collector is a hinged, two-part collar that easily snaps around the neck of the water pump. Installing this new part is quick and effective and reduces unnecessary water pump replacement. The coolant collector has a limited capacity to absorb coolant. If diagnosis with a pressure test of the coolant system indicates a failed pump seal, or if the customer concern is for coolant consumption, installing the coolant collector will not correct the condition. Coolant Collector Installation 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information subsection of the applicable Service Manual. 2. Place the open hinged coolant collector around the narrow neck area of the water pump. Position the hinged portion towards the front of the vehicle. Close the coolant collector, ensuring the tongue enter the latch. Exert pressure to lock the coolant collector in place until an audible click is heard, which ensure retention. 3. Lower the vehicle. Parts Information The coolant collector is available as part of an updated water pump kit and is also available separately. Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 01-06-02-012 > Dec > 01 > Water Pump - Coolant Weepage > Page 2775 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 01-06-02-012 > Dec > 01 > Water Pump Coolant Weepage Water Pump: All Technical Service Bulletins Water Pump - Coolant Weepage File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-02-012 Date: December, 2001 TECHNICAL Subject: Water Pump Weep (Install Coolant Collector) Models: 1996-1998 Buick Skylark 1996-2002 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am 1996-2002 Pontiac Sunfire with 2.4L Engine (VIN T - RPO LD9) Condition Some owners may comment on leakage of a few drops of coolant after parking their vehicle. A technician may notice that the water pump may show a staining around the weep hole. Cause The occasional drop of coolant and the staining may be the evidence of normal coolant weepage. The weep hole prevents normal coolant weepage from accumulating around the bearing seal. For more information on this normal condition, refer to Corporate Bulletin Number 00-06-02-009. Correction Replacing the water pump for this normal weepage is likely to result in a repeat of the customer concern. To address customer concerns and promote customer satisfaction, a coolant collector has been developed to trap and absorb normal weepage of the pump. The coolant collector is a hinged, two-part collar that easily snaps around the neck of the water pump. Installing this new part is quick and effective and reduces unnecessary water pump replacement. The coolant collector has a limited capacity to absorb coolant. If diagnosis with a pressure test of the coolant system indicates a failed pump seal, or if the customer concern is for coolant consumption, installing the coolant collector will not correct the condition. Coolant Collector Installation 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information subsection of the applicable Service Manual. 2. Place the open hinged coolant collector around the narrow neck area of the water pump. Position the hinged portion towards the front of the vehicle. Close the coolant collector, ensuring the tongue enter the latch. Exert pressure to lock the coolant collector in place until an audible click is heard, which ensure retention. 3. Lower the vehicle. Parts Information The coolant collector is available as part of an updated water pump kit and is also available separately. Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 01-06-02-012 > Dec > 01 > Water Pump Coolant Weepage > Page 2781 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 00-06-02-009 > Dec > 00 > Water Pump Weep (Normal Condition) Water Pump: All Technical Service Bulletins Water Pump - Weep (Normal Condition) File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-02-009 Date: December, 2000 INFORMATION Subject: Water Pump Weep (Normal condition) Models: 1996-1998 Buick Skylark 1996-2001 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am, Sunfire with 2.4 L Engine (VIN T - RPO LD9) Many coolant pumps may show a staining around the weep hole. This staining may be the evidence of normal coolant weepage. The weep hole permits the seal to breathe, allowing for expansion and contraction of the fluid and air around the outside of the seal assembly. This area of the pump housing provides a drain path to keep the bearing assembly seal dry. The weep hole also allows vapor to clear from the area to prevent crystalline formation. The seal face load springs control a balance of the hydrodynamic film required to lubricate the seal. As the pump stops turning, the spring squeezes most of the coolant from between the faces. This is known as weepage and is normal for automotive seals. It is normal for a drop or two of coolant to appear at the weep hole. It is not necessary to replace the coolant pump for weepage if you are working on the front of the engine and you notice a drop or a stain. The best tip is to be sure your diagnosis and repair is driven by the customer's concern. Follow Service Manual diagnostics. If the customer is actually seeing drops of coolant on the driveway, and you suspect the coolant pump, confirm your diagnosis with a pressure test of the coolant system and replace the pump if necessary. Finally, any time the coolant pump is serviced, or any other service is performed that requires removing the timing chain on the 2.4 L engine, it is critical that the chain tensioner reset procedure is followed correctly. Use the Service Manual procedure to release the timing chain tensioner. If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Water Pump: > 00-06-02-009 > Dec > 00 > Water Pump - Weep (Normal Condition) Water Pump: All Technical Service Bulletins Water Pump - Weep (Normal Condition) File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-02-009 Date: December, 2000 INFORMATION Subject: Water Pump Weep (Normal condition) Models: 1996-1998 Buick Skylark 1996-2001 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am, Sunfire with 2.4 L Engine (VIN T - RPO LD9) Many coolant pumps may show a staining around the weep hole. This staining may be the evidence of normal coolant weepage. The weep hole permits the seal to breathe, allowing for expansion and contraction of the fluid and air around the outside of the seal assembly. This area of the pump housing provides a drain path to keep the bearing assembly seal dry. The weep hole also allows vapor to clear from the area to prevent crystalline formation. The seal face load springs control a balance of the hydrodynamic film required to lubricate the seal. As the pump stops turning, the spring squeezes most of the coolant from between the faces. This is known as weepage and is normal for automotive seals. It is normal for a drop or two of coolant to appear at the weep hole. It is not necessary to replace the coolant pump for weepage if you are working on the front of the engine and you notice a drop or a stain. The best tip is to be sure your diagnosis and repair is driven by the customer's concern. Follow Service Manual diagnostics. If the customer is actually seeing drops of coolant on the driveway, and you suspect the coolant pump, confirm your diagnosis with a pressure test of the coolant system and replace the pump if necessary. Finally, any time the coolant pump is serviced, or any other service is performed that requires removing the timing chain on the 2.4 L engine, it is critical that the chain tensioner reset procedure is followed correctly. Use the Service Manual procedure to release the timing chain tensioner. If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Page 2791 Water Pump: Specifications Water Pump to Timing Chain Housing .................................................................................................................................................... 26 Nm (19 ft. lbs.) Water Pump to Water Pump Cover Bolts ........................................................................................................................................... 14 Nm (124 inch lbs.) Water Pump Cover-To-Block Bolts ........................................................................................................................................................ 26 Nm (19 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Page 2792 Water Pump: Service and Repair REMOVAL 1. Negative battery cable. 2. Drain and recover coolant. 3. Oxygen sensor connector. 4. Upper exhaust manifold heat shield and heater hose quick connect from heater outlet pipe. 5. Coolant inlet housing bolt through exhaust manifold. 6. Raise vehicle. 7. Exhaust manifold brace to manifold bolt. See Exhaust System. 8. Manifold to exhaust pipe bolts and heater outlet pipe bracket to bans bolt. 9. Coolant inlet housing assembly to water pump cover bolt. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Page 2793 10. Exhaust pipe from exhaust manifold. See Exhaust System. 11. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold. CAUTION: DO NOT rotate flex coupling more than 4 degrees (step 11) as damage may occur. 12. Coolant inlet pipe from oil pan. Leave the lower radiator hose attached and pull down on the coolant inlet pipe to disengage it from the water pump. Leave the coolant, inlet pipe hanging. 13. Lower vehicle. 14. Brake vacuum pipe from cam housing. See Brakes and Traction Control. 15. Exhaust manifold to cylinder head retaining nuts. 16. Exhaust manifold, seals and gaskets. See Exhaust System. 17. Front timing chain cover. See Engine. 18. Timing chain tensioner. See Engine. 19. Water pump cover to cylinder block bolts. 20. Water pump assembly to timing chain housing nuts (3). 21. Water pump and cover assembly. 22. Water pump cover to water pump assembly bolts (5). Clean all sealing surfaces. CAUTION: Prior to installing water pump read the entire procedure. Pay special attention to the tightening sequence to avoid part damage and to insure proper sealing. INSTALLATION 1. Water pump cover to water pump assembly and install bolts HAND TIGHT. 2. Cover to block bolts hand tight. 3. Pump to chain housing nuts hand tight. 4. Lube Oaring on coolant inlet pipe with an anti-freeze solution and slide pipe into water pump cover install bolts hand tight. 5. With specified gaps, torque in sequence as follows: a. Pump to chain housing nuts. Tighten nuts to 26 Nm (19 ft. lbs.). b. Pump cover to pump assembly. Tighten bolts to 14 Nm (124 inch lbs.). c. Cover to block, bottom bolt first. Tighten bolts to 26 Nm (19 ft. lbs.). d. Coolant inlet pipe assembly to cover. Tighten bolt to 14 Nm (124 inch lbs.). 6. Exhaust manifold and new gaskets. See Exhaust System. 7. Exhaust manifold to cylinder head retaining nuts. 8. Brake vacuum pipe to cam housing. 9. Raise vehicle. 10. Index exhaust manifold bolts into exhaust pipe flange. See Exhaust System. 11. Exhaust pipe to exhaust, manifold, land, heater outlet pipe bracket to trans. 12. Turn both exhaust bolts in evenly to avoid cocking the exhaust pipe and binding the bolts. Turn bolts in until fully seated. 13. Coolant inlet pipe to oil pan. Tighten bolt to 26 Nm (19 ft. lbs.). 14. Timing chain tensioner. See Engine. 15. Timing chain cover. See Engine. 16. Lower vehicle. 17. Exhaust manifold brace to manifold bolt. 18. Manifold to exhaust, pipe nuts. See Exhaust System. 19. Position heat sleeve on heater hose, then heater hose to the heater outlet pipe. Inspect quick connect retainer, pull heater hose to verify connection. 20. Upper heat shield to the exhaust manifold. 21. Oxygen sensor connector. 22. Fill radiator with coolant. 23. Negative battery cable. Tighten bolt to 16 Nm (12 ft. lbs.). Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Air Bleeder Screw, Coolant > Component Information > Specifications Air Bleeder Screw: Specifications Engine Coolant Air Bleed Pipe ........................................................................................................................................................... 14 Nm (124 inch lbs.) Engine Coolant Air Bleed Pipe Nut .......................................................................................................................................................... 42 Nm (31 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Customer Interest: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Coolant: Customer Interest Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Customer Interest: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2806 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Customer Interest: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2807 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 05-06-02-002B > Jan > 08 > Cooling System DEX-COOL(R) Coolant Leak Detection Dye Coolant: All Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information Coolant: All Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information > Page 2817 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information > Page 2818 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information > Page 2819 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Coolant: All Technical Service Bulletins Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2824 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2825 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 05-06-02-002B > Jan > 08 > Cooling System DEX-COOL(R) Coolant Leak Detection Dye Coolant: All Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information Coolant: All Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information > Page 2835 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information > Page 2836 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 00-06-02-006D > Aug > 06 > Cooling System Coolant Recycling Information > Page 2837 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Mixture .......................................................................................................................................................... 50/50 of water and ethylene glycol antifreeze Capacity ............................................................................................................................................... .................................................. 10.0 liters (10.5 qt) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2840 Coolant: Fluid Type Specifications ENGINE COOLANT A 50/50 mixture of clean water (preferably distilled) and use only GM Goodwrench(R) DEX-COOL(R) or Havoline(R) DEX-COOL(R) (orange-colored, silicate-free) coolant, or an approved recycled coolant conforming to GM Specification 6038-M (GM P/N 1052103). CAUTION: If silicate coolant is added to the cooling system, premature engine, heater core or radiator corrosion may result. In addition, the coolant will require change SOONER, at 50 000 km (30,000 miles) or 24 months. NOTE: With a complete flush and refill it is recommended to add Engine Coolant Supplement Sealer, (GM P/N 3634621 or equivalent). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2841 Coolant: Service Precautions CAUTION: When adding coolant it is important that you use GM Goodwrench DEX-COOL coolant. If coolant other than DEX-COOL is added to the system, the engine coolant will require change sooner - at 50,000 km (30,000 miles) or 24 months. Do not add cold water to the cooling system with the engine at or above operating temperature. Adding cold water causes rapid cooling, resulting in possible engine damage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2842 Coolant: Description and Operation NOTE: This vehicle was manufactured with GM Goodwrench DEX-COOL. DEX-COOL was developed to last for 240,000 km (150,000 miles) or 5 years whichever occurs first. Make sure only GM Goodwrench DEX-COOL is used when coolant is added or changed. A 50/50 mixture of ethylene glycol (DEX-COOL) and water will provide the following: ^ Freezing protection down to -37°C (-34°F). ^ Boiling protection up to 129°C (265°F). ^ Help keep the proper engine temperature. ^ Rust and corrosion protection. ^ Allow the sensors and switches to operate as designed. CAUTION: Do not use a solution stronger than 70 percent antifreeze. Pure antifreeze will freeze at -22°C (-8°F). DESCRIPTION Some coolant manufacturers are mixing other types of glycol in their coolant formulations; propylene glycol is the most common new ingredient However, propylene glycol is not recommended for use in GM vehicles that were manufactured with GM Goodwrench DEX-COOL. A hydrometer will not always provide a correct measurement of freeze protection when anything other than ethylene glycol and water is being tested. The degree of inaccuracy will vary depending on the proportion of other glycols present in the coolant. Hydrometers test the amount of glycol in a mixture by measuring the specific gravity of the mixture; the more ethylene glycol, the higher the float balls go, and the better the freeze protection. Because ethylene glycol and propylene glycol do not have the same specific gravities, hydrometer readings of mixtures containing propylene glycol give incorrect values. It is recommended that a "refractometer" be used when testing coolant. Refractometers test for the amount of glycol in a coolant mixture by measuring the speed of light as it passes through the fluid and are not affected by the specific gravity of the glycol. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Checking Coolant Level Coolant: Testing and Inspection Checking Coolant Level Check the coolant level in the radiator surge tank every time the hood is up. The level should be near appropriate mark when the system is cold. At normal operating temperature the coolant level should increase. Coolant should be added only to the reservoir or surge tank to raise level to the appropriate mark. If the pressure in the cooling system is too low, or if the coolant does not contain enough ethylene glycol antifreeze, the coolant will boil without the "Temp" indicator light coming on. Pure water could boil at 119°C (247°F) and the "Temp" indicator light would not come on, even with a 103 kPa (15 psi) cooling system. Pure water lacks the necessary rust inhibitors and coolant pump lubricant. The engine should never be run without the pressure cap, or with the cap loose, as the coolant will boil before the "Temp" indicator light comes on. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Checking Coolant Level > Page 2845 Coolant: Testing and Inspection Coolant Concentration Testing NOTE: Coolant testers with centigrade scale or fahrenheit scale can be used to check the antifreeze protection of the coolant. Make sure the refractometer markings are correct. Unless centigrade scale or fahrenheit scale has a provision for temperature correction, test the temperature at which testers are calibrated. If the coolant is warmer or cooler the reading may be incorrect. Follow the manufacturer's directions on tester being used. 1. Release the tip of the pump from the coolant tester housing. 2. Insert the tip of the pump into the surge tank. Make sure the tip of the pump is below the level of the coolant. 3. Press and release the bulb to get a sample. 4. Insert the tip of the pump into the cover plate opening. 5. Press the bulb and allow a few drops to fall onto the measuring surface. Do not open the plastic cover when taking readings because water evaporation can change the readings. 6. Point the coolant tester toward any light and look into the eyepiece. ^ Coolant protection reading is at the point where the dividing line between light and dark crosses the scale (anti-freeze protection is the scale on the right). ^ Temperature scale is reversed from a standard thermometer scale. ^ Below zero readings are on the upper half of the scale. ^ If the readings are not clear, the measuring surface was not cleaned and dried properly. Wipe dry and make a new test. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Service and Repair > Flushing Cooling System Coolant: Service and Repair Flushing Cooling System FLUSHING COOLING SYSTEM Various methods and equipment may be used to flush the system. If using special equipment such as a back flusher, follow the manufacturer's instructions. However, the thermostat should be removed before flushing the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Service and Repair > Flushing Cooling System > Page 2848 Coolant: Service and Repair Filling Cooling System FILLING NOTICE: When adding coolant. it is important that you use GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant mceting GM Specification 6277M. If silicated coolant is added to the system, premature engine. heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner - at 50,OOO km (30.000 miles) or 24 months. 1. Close the radiator drain valve and remove drain tuhe. 2. Install all engine block drain plugs if previously removed. ^ Use pipe sealer when insLalling drain plugs. 3. When adring coolant, it is important that you use GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant meeling GM Specification 6277M. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner - at 50,000 km (30,000 miles) or 24 months. ^ On vehicles produced with the 2.2L engine loosen the engine coolant alr bleed screw located on the top side of the engine coolant outlet. Add coolant until all sir is evacuated through air bleed, Tighten air bleed screw. Important: The bleeder screw must be tightened prior to starting the engine of the vehicle. Failure to tighten the bleeder screw may introduce air into the cooling system, resulting an incomplete coolant fill and possible engine overheating causing component failure. ^ When refilling the engine cooling system. add (2) crushed engine cooling system supplement sealer pellets GM part #3634621 or equivalent. 4. Fill the surge tank [0 the base of the filler neck. 5. Pressure cap onto the surge tank. ^ Block the drive wheels and firrnly apply the parking brake. Shift an automatic transaxle to "Park", or shift manual transaxle to Neutral. Run the engine until the upper radiater hose is hot. ^ Stop the engine. Observe the level of coolant in the surge tank or radiator. If not ahove the "Full" line, allow the engine to cool enough to relieve pressure, then carefully remove surge tank cap and add coolant. 6. Surge tank cap. ^ After servicing the cooling system, an occasional intermittent low coolant light (if equipped) may be encountered during some extreme driving maneuvers. This complaint should he eliminated by removing the surge tank cap and adding coolant to a level just at or above the "Cold Full" mark when the system is cold. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation The Low Coolant Switch is located in the coolant surge tank. The IPC contains the Low Coolant Indicator. The IPC lights this telltale when commanded to by the PCM. If the coolant level in the surge tank is low, the low coolant indicator will turn on and will remain on until the Ignition Switch is turned off or the coolant level in the surge tank is restored to a normal level. For a Bulb Check procedure, the IPC will light this telltale for 3 seconds when the IPC is initially powered up (ignition in "OFF/UNLOCK," "RUN," or "CRANK" positions) regardless of the serial data signal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations RH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2855 Coolant Level Sensor: Description and Operation This vehicle uses a "Low Coolant" warning switch. This switch is located in the coolant surge tank. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2856 Coolant Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Drain and recover the coolant. 2. Coolant hoses from radiator surge tank. 3. Low coolant connector. 4. Radiator surge tank bolt and tank. 5. Low coolant switch from tank. INSTALLATION PROCEDURE 1. Low coolant switch to tank. 2. Place tank in vehicle. Tighten bolt to 10 Nm (89 inch lbs.). 3. Coolant hoses to radiator surge tank. 4. Low coolant connector. 5. Fill cooling system at radiator surge tank to appropriate full mark. 6. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Surge Tank <--> [Coolant Reservoir] > Component Information > Technical Service Bulletins > Customer Interest for Radiator Surge Tank: > 73-83-09 > May > 97 > Cooling - Low Coolant Light On During Sustained Driving Radiator Surge Tank: Customer Interest Cooling - Low Coolant Light On During Sustained Driving File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-83-09 Date: May, 1997 Subject: Low Engine Coolant Light On During Sustained Driving at Moderate to High Engine RPM (Replace Cooling System Surge Tank) Models: 1997 Chevrolet Cavalier 1997 Pontiac Sunfire Built from SOP through December 31, 1996 Condition Some owners may comment that the low engine coolant light will illuminate during sustained driving at moderate to high engine RPM. Cause The design of the baffles in the cooling system surge tank coupled with the engine coolant air bleed pipe allow high coolant flow. This may allow the coolant sensor cavity in the surge tank to have an inadequate supply of coolant during sustained driving at moderate to high engine RPM. This may cause the low coolant light to illuminate even if the system is properly filled. Correction Verify that the system is properly filled and free of leaks. If the condition is still present, replace the cooling system surge tank with the revised design (see below for P/N's). Refer to the 1997 Service Manual. Parts Information Old P/N New P/N Description 22600776 22605500 For Chevrolet Cavalier and Pontiac Sunfire Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J3250 Tank, Radiator Use published Coolant Surge - labor operation R&R; or Replace time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Surge Tank <--> [Coolant Reservoir] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Surge Tank: > 73-83-09 > May > 97 > Cooling - Low Coolant Light On During Sustained Driving Radiator Surge Tank: All Technical Service Bulletins Cooling - Low Coolant Light On During Sustained Driving File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-83-09 Date: May, 1997 Subject: Low Engine Coolant Light On During Sustained Driving at Moderate to High Engine RPM (Replace Cooling System Surge Tank) Models: 1997 Chevrolet Cavalier 1997 Pontiac Sunfire Built from SOP through December 31, 1996 Condition Some owners may comment that the low engine coolant light will illuminate during sustained driving at moderate to high engine RPM. Cause The design of the baffles in the cooling system surge tank coupled with the engine coolant air bleed pipe allow high coolant flow. This may allow the coolant sensor cavity in the surge tank to have an inadequate supply of coolant during sustained driving at moderate to high engine RPM. This may cause the low coolant light to illuminate even if the system is properly filled. Correction Verify that the system is properly filled and free of leaks. If the condition is still present, replace the cooling system surge tank with the revised design (see below for P/N's). Refer to the 1997 Service Manual. Parts Information Old P/N New P/N Description 22600776 22605500 For Chevrolet Cavalier and Pontiac Sunfire Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J3250 Tank, Radiator Use published Coolant Surge - labor operation R&R; or Replace time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Surge Tank <--> [Coolant Reservoir] > Component Information > Technical Service Bulletins > Page 2870 Radiator Surge Tank: Specifications Surge Tank Bolts ................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Surge Tank Inlet Hose Clip .............................. ..................................................................................................................................... 10 Nm (89 inch lbs.) Surge Tank Cap ................................................................................................................... .................................................................... 4 Nm (35 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Surge Tank <--> [Coolant Reservoir] > Component Information > Technical Service Bulletins > Page 2871 Radiator Surge Tank: Description and Operation A plastic radiator surge tank is incorporated in the cooling system. Pressurized coolant will circulate in the tank entering from the top inlet hose attached from the engine and radiator and exiting the bottom outlet hose to the lower radiator hose. The tank is at the highest point of the cooling system. This will allow any air or vapor exceeding the pressure cap rating to exit the tank. When the coolant is "cold" the level should be at the appropriate mark on the tank. All engines incorporate a "Low Coolant" indicator located inside the tank. This indicator is serviceable only by replacing the individual switch component. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Engine Cooling Fan Bolt ...................................................................................................................... ................................................... 6 Nm (53 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications > Page 2876 RH Front Of Engine And Cooling Fan Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Radiator Cooling Fan Motor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2911 Radiator Cooling Fan Motor: Description and Operation DESCRIPTION An electric coolant fan aids air flow through the radiator. The fan is driven by an electric motor attached to the radiator support. The fan motor is activated by coolant temperature. If the vehicle is equipped with air conditioning, a switch can activate the fan motor when the compressor is operating. WARNING: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep, hands, clothing and tools away from any underhood electric fan. OPERATION The PCM regulates voltage to the coolant fan relay, which operates the fan when the engine coolant temperature exceeds 106°C (223°F). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2912 Radiator Cooling Fan Motor: Service and Repair Note: The manufacturer does not provide a procedure for motor removal/replacement from the fan assembly. REMOVE 1. Negative battery cable. 2. Raise and support vehicle. 3. Coolant fan mounting bolt. 4. Electrical connector from coolant fan. 5. Coolant fan assembly out through the bottom. INSTALL 1. Coolant fan assembly in through the bottom. 2. Electrical connector to coolant fan. 3. Coolant fan mounting bolt. Tighten bolt to 6 Nm (53 inch lbs.). 4. Lower vehicle. 5. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations LH Center Of Engine Compartment Underhood fuse relay center Front View Of Engine Compartment Fuse/Relay Center Identification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Left Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 2921 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2922 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperatures produce a high resistance (100,000 ohms at -40°C/-40°F), while high temperatures cause low resistance (70 ohms at 130°C/266°F). The Powertrain Control Module (PCM) uses this signal to determine the engine coolant temperature. OPERATION The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the ECT sensor's resistance is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table will lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2923 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection A scan tool displays the engine temperature in degrees Celsius. After the engine is started, the temperature should rise steadily to about 90°C (194°F) then stabilize when the thermostat opens. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2924 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal Procedure Notice: Care must be taken when handling an Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. Installation Procedure 1. Coat only the threads with sealer. 2. Install the ECT sensor in the engine, fully driven, seated and not stripped. 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2929 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2930 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2931 Heater Core: Specifications Heater Core Cover Screws .................................................................................................................. ......................................................... 1 N.m (9 lb. in.) Heater Core Shroud Screws ................................................................................................................ .......................................................... 1 N.m (9 lb. in.) Heater Core Strap Screws ................................................................................................................... .......................................................... 1 N.m (9 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2932 Heater Core: Locations Heater Module - Disassembled View (1 Of 2) Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2933 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2934 Heater Core: Service and Repair Heater Module - Disassembled View (1 Of 2) Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Raise vehicle. 4. Heater hoses from heater core. 5. Lower vehicle. 6. I/P. 7. Heater core outlet. 8. Heater core cover. ^ There is a mounting screw located in a recess in the center of the cover 9. Heater core mounting clamps and heater core. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2935 Install or Connect 1. Heater core and heater core mounting clamps. 2. Heater core cover. 3. Heater core outlet. 4. I/P. 5. Raise vehicle. 6. Heater hoses to heater core. 7. Lower vehicle. 8. Fill cooling system and check for leaks. 9. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2936 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Specifications Heater Hose: Specifications Heater Outlet Pipe Nut ........................................................................................................................ ...................................................... 25 N.m (18 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses Heater Hose Routing - 2.4L Check all heater hose routing for installation to avoid contact with any obstruction that could result in a damaged hose. Some hoses are equipped with conduit in areas where rubbing may occur. Always reinstall conduit or heat sleeves in the same location when replacing a hose. Tool Required: J 42202 Quick Connect Remover Remove or Disconnect 1. Drain engine coolant. 2. Heater hose from heater pipe by squeezing tabs on quick-connect. ^ J 42202 can be used to separate quick-connect and retainer from pipe. 3. Heater hose from inlet housing. 4. Raise vehicle. 5. Heater hoses from heater core. Install or Connect 1. Heater hoses to heater core. 2. Lower vehicle. 3. Top heater core hose to inlet housing. 4. Heater hose to heater pipe quick-connect, pull to verify connection. 5. Refill engine coolant. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 2942 Heater Hose: Service and Repair Heater Outlet Pipe ^ Part of the coolant pump outlet assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 2943 Heater Hose: Service and Repair Quick Connect Retainer The quick connect retainer can be removed from the heater pipe and replaced if necessary. it is recommended that the retainer be replaced whenever the quick-connect is disconnected. If the retainer is to be reused, the use of J 42202 is recommended. Tool Required: J 42202 Quick Connect Remover 1. Clamp J 42202 around the heater pipe. 2. Slide J 42202 under the quick connect retainer 3. Apply pressure towards the quick connect retainer until the ramps release from the pipe. 4. Remove the quick connect retainer from the pipe. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation The Low Coolant Switch is located in the coolant surge tank. The IPC contains the Low Coolant Indicator. The IPC lights this telltale when commanded to by the PCM. If the coolant level in the surge tank is low, the low coolant indicator will turn on and will remain on until the Ignition Switch is turned off or the coolant level in the surge tank is restored to a normal level. For a Bulb Check procedure, the IPC will light this telltale for 3 seconds when the IPC is initially powered up (ignition in "OFF/UNLOCK," "RUN," or "CRANK" positions) regardless of the serial data signal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gage indicates the temperature of the engine coolant with the Ignition Switch in the "RUN" position. A Coolant Temperature Sensor in the engine changes resistance with coolant temperature. As coolant temperature increases, the resistance of the sensor decreases. The PCM reads the resistance value and assigns an appropriate value between 0 and 255 counts where it is transmitted to the IPC via serial data. The IPC reads the count value and assigns a deflection value which causes the needle in the gages to turn. The gage will read from 37.8 deg C to 122 deg C (100 deg. F to 253 deg. F). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This switch activates a warning lamp in the instrument cluster if the engine overheats. With optional instrumentation, a temperature gage replaces the warning lamp. The temperature gage is driven with a transducer. The engine coolant temperature switch is not serviceable. If it is faulty, it should be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Description and Operation Radiator Drain Plug: Description and Operation The radiator drain cock is located on the bottom of the left radiator tank. The drain cock assembly includes the drain cock and the drain cock seal. Use this drain whenever coolant needs to be removed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation DESCRIPTION A pressure-vent cap is used to allow a buildup of 103 kPa (15 psi) in the cooling system. This pressure raises the boiling point of coolant to approximately 125°C (262°F) at sea level. OPERATION The pressure-type surge tank cap contains a blow-off (pressure) valve and a vacuum (atmospheric) valve. The pressure valve is held against its seat by a heavy spring. This spring protects the radiator by relieving pressure exceeding 103 kPa (15 psi). To prevent radiator collapse caused by vacuum as the engine cools, the vacuum valve prevents excessive pressure differences from occurring between the cooling system and the atmosphere. To safely remove the cap from a cool system, rotate the cap slowly-counterclockwise and allow any pressure-to relieve. Continue to rotate cap counterclockwise and lift off the cap. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Page 2961 Radiator Cap: Testing and Inspection ^ Tools Required, or equivalent: J 24460-01 Cooling System Pressure Tester J 24460-92 Cooling System Pressure Test Adapter INSPECT ^ Hose connections for leaks. ^ Surge tank cap for loss of pressure using cooling system pressure test adapter and cooling system pressure tester. If the cap does not hold the rated pressure, replace the surge tank pressure cap. ^ Make sure that the correct cap is being used. PRESSURE TEST CAUTION: Pressures above 138 kPa (20 psi) should not be used when testing the cooling system. Pressures over 138 kPa (20 psi) will damage the radiator. 1. Inspect the connections for leaks. Repair as required. 2. Remove the surge tank cap. 3. Attach cooling system pressure test adapter and cooling system pressure tester to the surge tank. ^ Follow the instructions supplied with cooling system pressure tester. 4. Build up pressure to no more than 138 kPa (20 psi). 5. The system should hold the pressure for about two minutes. ^ If a measurable amount of pressure drops in less than two minutes, check for a leak. ^ Mark the leaking area. Remove and replace the radiator if necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Specifications Radiator Hose: Specifications Radiator Outlet Hose To Water Pump Cover ..................................................................................................................................... 14 Nm (124 inch lbs.) Radiator Outlet Hose To Engine Oil Pan .................................................................................................................................................. 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Specifications > Page 2965 Radiator Hose: Testing and Inspection Inspect the condition of all hoses and clamps. Hoses should be flexible and show no signs of bulging. Inspect hoses for cracks, cuts, kinks and areas of possible leaks. Check the alignment of the hoses using the reference marks for proper orientation of hoses. Inspect the brackets, supports, ties and clamps. Replace or adjust as needed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Specifications > Page 2966 Radiator Hose: Service and Repair REMOVAL PROCEDURE 1. Negative battery cable. 2. Drain and recover the radiator so the level of the coolant is below the hose being removed. 3. Radiator inlet hose from the radiator and engine coolant outlet. 4. Radiator outlet hose from the radiator and radiator outlet pipe and surge tank. CAUTION: Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break. INSTALLATION PROCEDURE 1. Radiator outlet hose to the radiator and radiator outlet pipe and surge tank. 2. Radiator inlet hose to the radiator and engine coolant outlet. 3. Refill radiator. 4. Negative battery cable. 5. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations LH Center Of Engine Compartment Underhood fuse relay center Front View Of Engine Compartment Fuse/Relay Center Identification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Seals and Gaskets, Cooling System > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Thermostat Gasket: Customer Interest Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Seals and Gaskets, Cooling System > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2980 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Seals and Gaskets, Cooling System > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2981 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Seals and Gaskets, Cooling System > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor Thermostat Gasket: All Technical Service Bulletins Cooling System - Coolant Loss/Leakage/Lamp On/or Odor File In Section: 6 - Engine Bulletin No.: 67-62-04 Date: December, 1996 Subject: Coolant Loss, Visible Coolant Leakage, Low Coolant Lamp On, or Coolant Odor, Caused by Coolant Leakage (Install a New Thermostat Gasket) Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Sunfire, Grand Am with 2.2L, 2.4L Engines (VINs 4, T - RPOs LN2, LD9) Built before October, 1996 Condition Some customers may comment about engine coolant loss, low coolant lamp on, visible coolant, or a coolant odor from the engine compartment. Some owners may be unable to distinguish the coolant from transmission fluid due to its orange color. Cause Some 1996 and 1997 J and N model cars equipped with 2.4 Liter (VIN Engine Code T RPO LD9) engines may exhibit coolant leakage at the joint where the radiator outlet pipe is connected to the coolant pump cover. In addition, some of these vehicles may exhibit leakage at the joint between the cooling system air bleed pipe and the coolant outlet. On 2.2 Liter engines (VIN Engine Code 4 RPO LN2) coolant leakage may occur between the thermostat housing and the coolant inlet pipe. Correction On vehicles exhibiting leakage at the thermostat gasket joint, install a new thermostat gasket with part number 24576633, using procedures outlined in the Engine Cooling Section on the Service Manual. 1. If any of the previously noted conditions occur, first inspect the vehicle per the Engine Cooling Section of the applicable Service Manual. If no other cause is found for the condition, proceed with step 2. 2. Inspect the joint between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines) for signs of leakage. Pressure or dye testing may be necessary in some instances. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Seals and Gaskets, Cooling System > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2987 3. If any signs of coolant leakage are noted, replace the thermostat gasket using the procedures in the Engine Cooling Section of the Service Manual. 4. If the thermostat seal has been replaced with part number 24576633 and there continues to be leakage between the radiator outlet pipe (thermostat housing on 2.2L engines) and the coolant pump cover (coolant inlet pipe on 2.2L engines), replace the thermostat housing on 2.2L engines or the radiator outlet pipe on 2.4L engines. Important: Do not attempt to install any seal other than 24576633 into this joint! If an attempt is made to install a thicker seal, the flange on the radiator outlet pipe will be distorted when it is tightened creating an additional leak. If any attempt has been made to repair the leak with a thicker seal, the thermostat housing on 2.2L (RPO LN2) engines or the radiator outlet pipe on 2.4L (RPO LD9) engines should be replaced to prevent leaks caused by distortion. Important: DO NOT REPLACE 82°C (180°F) 1996 THERMOSTAT WITH ANY OTHER THERMOSTAT. If poor heater performance is noted, follow diagnostic procedures in Section 1A of the appropriate Service Manual. In some instances of poor heater performance, 1995 91°C (195°F) thermostats have been installed in 1996 2.2L LN2 and 2.4L LD9 engines. The 1996 thermostat used for the inlet thermostat system is unique and cannot be replaced with a thermostat from an outlet side thermostat application. If a 1995 91°C (195°F) thermostat is used to replace a 1996 82°C (180°F) thermostat, the following conditions WILL occur: ^ 91°C (195°F) (1995) vs. 82°C (180°F) (1996) will cause the 1996 2.2L LN2 and 2.4L LD9 engines to run hotter at low RPM. ^ A lighter spring in the 91°C (195°F) (1995) thermostat will allow the thermostat to be pulled open by coolant flow at higher RPM, causing the engine to run too cold and will cause poor heater performance at highway speeds. 5. On vehicles equipped with the 2.4 Liter (VIN Engine Code T RPO LD9) engine, inspect the sealing of the joint between the coolant outlet and the cooling system air bleed pipe. If any leakage is noted, replace the coolant outlet, GM P/N 24575259, air bleed pipe, GM P/N 24574205, and "0" ring seal, GM P/N 24573057. Use silicone based lubricant, GM P/N 12345579, when installing the new air bleed pipe and seal into the coolant outlet. Parts Information Whenever ordering parts, refer to the part numbers as shown. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Seals and Gaskets, Cooling System > Thermostat Gasket, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Gasket: > 67-62-04 > Dec > 96 > Cooling System - Coolant Loss/Leakage/Lamp On/or Odor > Page 2988 For vehicles repaired under warranty, use: as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations RH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2993 Coolant Level Sensor: Description and Operation This vehicle uses a "Low Coolant" warning switch. This switch is located in the coolant surge tank. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2994 Coolant Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Drain and recover the coolant. 2. Coolant hoses from radiator surge tank. 3. Low coolant connector. 4. Radiator surge tank bolt and tank. 5. Low coolant switch from tank. INSTALLATION PROCEDURE 1. Low coolant switch to tank. 2. Place tank in vehicle. Tighten bolt to 10 Nm (89 inch lbs.). 3. Coolant hoses to radiator surge tank. 4. Low coolant connector. 5. Fill cooling system at radiator surge tank to appropriate full mark. 6. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Left Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 3000 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3001 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperatures produce a high resistance (100,000 ohms at -40°C/-40°F), while high temperatures cause low resistance (70 ohms at 130°C/266°F). The Powertrain Control Module (PCM) uses this signal to determine the engine coolant temperature. OPERATION The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the ECT sensor's resistance is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table will lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3002 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection A scan tool displays the engine temperature in degrees Celsius. After the engine is started, the temperature should rise steadily to about 90°C (194°F) then stabilize when the thermostat opens. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3003 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal Procedure Notice: Care must be taken when handling an Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. Installation Procedure 1. Coat only the threads with sealer. 2. Install the ECT sensor in the engine, fully driven, seated and not stripped. 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gage indicates the temperature of the engine coolant with the Ignition Switch in the "RUN" position. A Coolant Temperature Sensor in the engine changes resistance with coolant temperature. As coolant temperature increases, the resistance of the sensor decreases. The PCM reads the resistance value and assigns an appropriate value between 0 and 255 counts where it is transmitted to the IPC via serial data. The IPC reads the count value and assigns a deflection value which causes the needle in the gages to turn. The gage will read from 37.8 deg C to 122 deg C (100 deg. F to 253 deg. F). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This switch activates a warning lamp in the instrument cluster if the engine overheats. With optional instrumentation, a temperature gage replaces the warning lamp. The temperature gage is driven with a transducer. The engine coolant temperature switch is not serviceable. If it is faulty, it should be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Range 82 Degrees C 180 Degrees F Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3013 Thermostat: Description and Operation DESCRIPTION The 2.2L and 2.4L engines use a pellet-type thermostat in the radiator outlet passage to control the flow of coolant. This provides faster engine warm-up and regulates coolant temperatures. A wax pellet or power element in the thermostat expands when heated and contracts when cooled. The valve is connected to the power element. When the wax expands, the piston pushes against the flange and opens the thermostat. As the pellet cools, contraction allows a spring to close the valve. Thus, the valve remains closed while the coolant is cold. This prevents coolant circulation through the radiator, but allows the coolant to circulate through the engine to warm it quickly and evenly. OPERATION As the engine becomes warm, the pellet expands and the thermostat valve opens. This lets coolant flow through the radiator, where heat is passed through the radiator walls. This opening and closing of the thermostat valve allows enough coolant to enter the radiator to keep the engine within specified temperature limits. Both engines use a 82°C (180°F) thermostat. Using a thermostat rated above this control temperature is not recommended. Higher temperature thermostats will not provide faster warm-up, since their valves remain tightly closed until the control temperature is reached, as does a lower temperature thermostat. The thermostat must be installed with the pointed end facing toward the radiator. Incorrect installation of the thermostat may cause the engine to overheat. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3014 Thermostat: Service and Repair REMOVE 1. Negative battery cable. 2. Drain and recover coolant until level is below thermostat. 3. Exhaust manifold heat shield. 4. Cover to outlet pipe bolt through exhaust manifold runners. 5. Raise and support vehicle. 6. Radiator hose from outlet pipe. 7. Outlet pipe to oil pan bolt. 8. Cover to outlet pipe bolt. 9. Thermostat. 10. Clean ^ Outlet pipe mating surface. ^ Cover mating surface. INSTALL 1. Thermostat. 2. Cover to outlet pipe bolt. Tighten Tighten bolts to 14 N.m (124 inch lbs.). 3. Outlet pipe to oil pan bolt. Tighten Tighten pipe to oil pan 26 N.m (19 ft. lbs.). 4. Radiator hose to outlet pipe. 5. Lower vehicle. 6. Cover to outlet pipe bolt through exhaust manifold runner. 7. Exhaust manifold heat shield. 8. Fill cooling system. 9. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 01-06-02-012 > Dec > 01 > Water Pump - Coolant Weepage Water Pump: Customer Interest Water Pump - Coolant Weepage File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-02-012 Date: December, 2001 TECHNICAL Subject: Water Pump Weep (Install Coolant Collector) Models: 1996-1998 Buick Skylark 1996-2002 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am 1996-2002 Pontiac Sunfire with 2.4L Engine (VIN T - RPO LD9) Condition Some owners may comment on leakage of a few drops of coolant after parking their vehicle. A technician may notice that the water pump may show a staining around the weep hole. Cause The occasional drop of coolant and the staining may be the evidence of normal coolant weepage. The weep hole prevents normal coolant weepage from accumulating around the bearing seal. For more information on this normal condition, refer to Corporate Bulletin Number 00-06-02-009. Correction Replacing the water pump for this normal weepage is likely to result in a repeat of the customer concern. To address customer concerns and promote customer satisfaction, a coolant collector has been developed to trap and absorb normal weepage of the pump. The coolant collector is a hinged, two-part collar that easily snaps around the neck of the water pump. Installing this new part is quick and effective and reduces unnecessary water pump replacement. The coolant collector has a limited capacity to absorb coolant. If diagnosis with a pressure test of the coolant system indicates a failed pump seal, or if the customer concern is for coolant consumption, installing the coolant collector will not correct the condition. Coolant Collector Installation 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information subsection of the applicable Service Manual. 2. Place the open hinged coolant collector around the narrow neck area of the water pump. Position the hinged portion towards the front of the vehicle. Close the coolant collector, ensuring the tongue enter the latch. Exert pressure to lock the coolant collector in place until an audible click is heard, which ensure retention. 3. Lower the vehicle. Parts Information The coolant collector is available as part of an updated water pump kit and is also available separately. Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 01-06-02-012 > Dec > 01 > Water Pump - Coolant Weepage > Page 3023 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 01-06-02-012 > Dec > 01 > Water Pump Coolant Weepage Water Pump: All Technical Service Bulletins Water Pump - Coolant Weepage File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-02-012 Date: December, 2001 TECHNICAL Subject: Water Pump Weep (Install Coolant Collector) Models: 1996-1998 Buick Skylark 1996-2002 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am 1996-2002 Pontiac Sunfire with 2.4L Engine (VIN T - RPO LD9) Condition Some owners may comment on leakage of a few drops of coolant after parking their vehicle. A technician may notice that the water pump may show a staining around the weep hole. Cause The occasional drop of coolant and the staining may be the evidence of normal coolant weepage. The weep hole prevents normal coolant weepage from accumulating around the bearing seal. For more information on this normal condition, refer to Corporate Bulletin Number 00-06-02-009. Correction Replacing the water pump for this normal weepage is likely to result in a repeat of the customer concern. To address customer concerns and promote customer satisfaction, a coolant collector has been developed to trap and absorb normal weepage of the pump. The coolant collector is a hinged, two-part collar that easily snaps around the neck of the water pump. Installing this new part is quick and effective and reduces unnecessary water pump replacement. The coolant collector has a limited capacity to absorb coolant. If diagnosis with a pressure test of the coolant system indicates a failed pump seal, or if the customer concern is for coolant consumption, installing the coolant collector will not correct the condition. Coolant Collector Installation 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information subsection of the applicable Service Manual. 2. Place the open hinged coolant collector around the narrow neck area of the water pump. Position the hinged portion towards the front of the vehicle. Close the coolant collector, ensuring the tongue enter the latch. Exert pressure to lock the coolant collector in place until an audible click is heard, which ensure retention. 3. Lower the vehicle. Parts Information The coolant collector is available as part of an updated water pump kit and is also available separately. Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 01-06-02-012 > Dec > 01 > Water Pump Coolant Weepage > Page 3029 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 00-06-02-009 > Dec > 00 > Water Pump Weep (Normal Condition) Water Pump: All Technical Service Bulletins Water Pump - Weep (Normal Condition) File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-02-009 Date: December, 2000 INFORMATION Subject: Water Pump Weep (Normal condition) Models: 1996-1998 Buick Skylark 1996-2001 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am, Sunfire with 2.4 L Engine (VIN T - RPO LD9) Many coolant pumps may show a staining around the weep hole. This staining may be the evidence of normal coolant weepage. The weep hole permits the seal to breathe, allowing for expansion and contraction of the fluid and air around the outside of the seal assembly. This area of the pump housing provides a drain path to keep the bearing assembly seal dry. The weep hole also allows vapor to clear from the area to prevent crystalline formation. The seal face load springs control a balance of the hydrodynamic film required to lubricate the seal. As the pump stops turning, the spring squeezes most of the coolant from between the faces. This is known as weepage and is normal for automotive seals. It is normal for a drop or two of coolant to appear at the weep hole. It is not necessary to replace the coolant pump for weepage if you are working on the front of the engine and you notice a drop or a stain. The best tip is to be sure your diagnosis and repair is driven by the customer's concern. Follow Service Manual diagnostics. If the customer is actually seeing drops of coolant on the driveway, and you suspect the coolant pump, confirm your diagnosis with a pressure test of the coolant system and replace the pump if necessary. Finally, any time the coolant pump is serviced, or any other service is performed that requires removing the timing chain on the 2.4 L engine, it is critical that the chain tensioner reset procedure is followed correctly. Use the Service Manual procedure to release the timing chain tensioner. If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Water Pump: > 00-06-02-009 > Dec > 00 > Water Pump - Weep (Normal Condition) Water Pump: All Technical Service Bulletins Water Pump - Weep (Normal Condition) File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-02-009 Date: December, 2000 INFORMATION Subject: Water Pump Weep (Normal condition) Models: 1996-1998 Buick Skylark 1996-2001 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am, Sunfire with 2.4 L Engine (VIN T - RPO LD9) Many coolant pumps may show a staining around the weep hole. This staining may be the evidence of normal coolant weepage. The weep hole permits the seal to breathe, allowing for expansion and contraction of the fluid and air around the outside of the seal assembly. This area of the pump housing provides a drain path to keep the bearing assembly seal dry. The weep hole also allows vapor to clear from the area to prevent crystalline formation. The seal face load springs control a balance of the hydrodynamic film required to lubricate the seal. As the pump stops turning, the spring squeezes most of the coolant from between the faces. This is known as weepage and is normal for automotive seals. It is normal for a drop or two of coolant to appear at the weep hole. It is not necessary to replace the coolant pump for weepage if you are working on the front of the engine and you notice a drop or a stain. The best tip is to be sure your diagnosis and repair is driven by the customer's concern. Follow Service Manual diagnostics. If the customer is actually seeing drops of coolant on the driveway, and you suspect the coolant pump, confirm your diagnosis with a pressure test of the coolant system and replace the pump if necessary. Finally, any time the coolant pump is serviced, or any other service is performed that requires removing the timing chain on the 2.4 L engine, it is critical that the chain tensioner reset procedure is followed correctly. Use the Service Manual procedure to release the timing chain tensioner. If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Page 3039 Water Pump: Specifications Water Pump to Timing Chain Housing .................................................................................................................................................... 26 Nm (19 ft. lbs.) Water Pump to Water Pump Cover Bolts ........................................................................................................................................... 14 Nm (124 inch lbs.) Water Pump Cover-To-Block Bolts ........................................................................................................................................................ 26 Nm (19 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Page 3040 Water Pump: Service and Repair REMOVAL 1. Negative battery cable. 2. Drain and recover coolant. 3. Oxygen sensor connector. 4. Upper exhaust manifold heat shield and heater hose quick connect from heater outlet pipe. 5. Coolant inlet housing bolt through exhaust manifold. 6. Raise vehicle. 7. Exhaust manifold brace to manifold bolt. See Exhaust System. 8. Manifold to exhaust pipe bolts and heater outlet pipe bracket to bans bolt. 9. Coolant inlet housing assembly to water pump cover bolt. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Page 3041 10. Exhaust pipe from exhaust manifold. See Exhaust System. 11. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold. CAUTION: DO NOT rotate flex coupling more than 4 degrees (step 11) as damage may occur. 12. Coolant inlet pipe from oil pan. Leave the lower radiator hose attached and pull down on the coolant inlet pipe to disengage it from the water pump. Leave the coolant, inlet pipe hanging. 13. Lower vehicle. 14. Brake vacuum pipe from cam housing. See Brakes and Traction Control. 15. Exhaust manifold to cylinder head retaining nuts. 16. Exhaust manifold, seals and gaskets. See Exhaust System. 17. Front timing chain cover. See Engine. 18. Timing chain tensioner. See Engine. 19. Water pump cover to cylinder block bolts. 20. Water pump assembly to timing chain housing nuts (3). 21. Water pump and cover assembly. 22. Water pump cover to water pump assembly bolts (5). Clean all sealing surfaces. CAUTION: Prior to installing water pump read the entire procedure. Pay special attention to the tightening sequence to avoid part damage and to insure proper sealing. INSTALLATION 1. Water pump cover to water pump assembly and install bolts HAND TIGHT. 2. Cover to block bolts hand tight. 3. Pump to chain housing nuts hand tight. 4. Lube Oaring on coolant inlet pipe with an anti-freeze solution and slide pipe into water pump cover install bolts hand tight. 5. With specified gaps, torque in sequence as follows: a. Pump to chain housing nuts. Tighten nuts to 26 Nm (19 ft. lbs.). b. Pump cover to pump assembly. Tighten bolts to 14 Nm (124 inch lbs.). c. Cover to block, bottom bolt first. Tighten bolts to 26 Nm (19 ft. lbs.). d. Coolant inlet pipe assembly to cover. Tighten bolt to 14 Nm (124 inch lbs.). 6. Exhaust manifold and new gaskets. See Exhaust System. 7. Exhaust manifold to cylinder head retaining nuts. 8. Brake vacuum pipe to cam housing. 9. Raise vehicle. 10. Index exhaust manifold bolts into exhaust pipe flange. See Exhaust System. 11. Exhaust pipe to exhaust, manifold, land, heater outlet pipe bracket to trans. 12. Turn both exhaust bolts in evenly to avoid cocking the exhaust pipe and binding the bolts. Turn bolts in until fully seated. 13. Coolant inlet pipe to oil pan. Tighten bolt to 26 Nm (19 ft. lbs.). 14. Timing chain tensioner. See Engine. 15. Timing chain cover. See Engine. 16. Lower vehicle. 17. Exhaust manifold brace to manifold bolt. 18. Manifold to exhaust, pipe nuts. See Exhaust System. 19. Position heat sleeve on heater hose, then heater hose to the heater outlet pipe. Inspect quick connect retainer, pull heater hose to verify connection. 20. Upper heat shield to the exhaust manifold. 21. Oxygen sensor connector. 22. Fill radiator with coolant. 23. Negative battery cable. Tighten bolt to 16 Nm (12 ft. lbs.). Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Flange Attaching Bolt .......................................................................................................................... ..................................................... 30 Nm (22 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 3046 Component Location Views Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 3047 Catalytic Converter: Description and Operation PURPOSE The control module must monitor the Three-Way catalyst system (TWC) for efficiency. In order to accomplish this, the control module monitors the pre-catalyst and post-catalyst oxygen sensors. When the TWC is operating properly, the post-catalyst (2) oxygen sensor will have significantly less activity than the pre-catalyst (1) oxygen sensor. The TWC stores oxygen as needed during its normal reduction and oxidation process. The TWC releases oxygen as needed during its normal reduction and oxidation process. The control module calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst oxygen sensor's voltage levels. OPERATION Whenever the voltage levels of the post-catalyst (2) oxygen sensor nears the voltage levels that of the pre-catalyst (1) oxygen sensor, the catalysts efficiency is degraded. Stepped or staged testing levels allow the control module to statistically filter test information. This prevents falsely passing or falsely failing the oxygen storage capacity test. The calculations performed by the on-board diagnostic system are very complex. For this reason, do not use post catalyst oxygen sensor activity in order to determine the oxygen storage capacity unless directed by the electronic service information Three stages are used in order to monitor catalyst efficiency. Failure of the first stage indicates that the catalyst requires further testing in order to determine catalyst efficiency. Failure of the second stage indicates that the catalyst may be degraded. The third stage then looks at the inputs from the pre and post O2 sensors more closely before determining if the catalyst is indeed degraded. This further statistical processing is done to increase the accuracy of oxygen storage capacity type monitoring. Failing the first (stage 0) or second (stage 1) test Does Not indicate a failed catalyst. The catalyst may be marginal or the fuel sulfur content could be very high. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an Aftermarket catalyst does not contain the same amount of cerium as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. The EVAP system uses a switch located in the purge line between the canister and the purge valve in order to detect when the purge is occurring. This switch senses the flow from the engine through the purge valve. When no purge is present, the switch is closed, applying a 12 volt signal to the control module as a NO PURGE signal. When canister purging occurs, the switch opens, interrupting off the 12 volt signal to the control module. A scan tool display will indicate that purge is occurring. Clogging of the canister fresh air vent could allow the purge hose between the switch and canister to trap vacuum with the purge valve closed. This would result in a diagnostic indication of a purge valve stuck open or a vacuum switch failure. Similarly, leaks or blockages in the purge hoses may result in misdiagnosis of the purge valve or vacuum switch. When servicing a purge valve diagnostic trouble code, check the canister fresh air vent, vacuum switch and the integrity of all purge hoses prior to servicing the valve. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 3048 Catalytic Converter: Service and Repair CAUTION: When a flex decoupler joint is moved from the normal mounting position it is possible to over-flex and damage the joint. Always support the flex decoupler joint and pipe assembly to avoid over-flexing. The flex decoupler joint is designed to flex a maximum of six degrees which is equivalent to the pipes connected to the joint moving no more than 1 inch for every 1 foot length of pipe, (if the pipe connected to the joint is 3 feet long, the end of the pipe could be moved a maximum of 3 inches). REMOVAL PROCEDURE 1. Raise and support vehicle. 2. Support three way catalytic converter. 3. Intermediate pipe from three way catalytic converter. 4. Exhaust manifold pipe assembly from exhaust manifold. 5. Exhaust manifold and three way catalytic converter seals. 6. Clean flange surfaces. INSTALLATION PROCEDURE 1. Exhaust manifold and three way catalytic converter seals. 2. Exhaust manifold pipe assembly to exhaust manifold. 3. Intermediate pipe to three way catalytic converter. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Upper Heat Shield to the Manifold Bolts ................................................................................................................................................. 26 Nm (19 ft. lbs.) To the Cylinder Head Nuts ................................................................................................ ....................................................................... 42 Nm (31 ft. lbs.) To the Cylinder Head Studs ........... ....................................................................................................................................................... 11 Nm (97 inch lbs.) Brace to the Exhaust Manifold Bolt ......................................................................................................................................................... 56 Nm (41 ft. lbs.) Brace to the Oil Pan Nuts ........................................................................................... .............................................................................. 26 Nm (19 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3052 Exhaust Manifold: Description and Operation The exhaust manifold is cast iron. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3053 Exhaust Manifold: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the 02S (Oxygen sensor) connector. 3. Raise and support the vehicle. 4. Remove the exhaust manifold brace to manifold fasteners. 5. Remove the upper heat shield. CAUTION: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3054 6. Remove the manifold to the exhaust flex decoupler fasteners. 7. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold. 8. Lower the vehicle. 9. Remove the exhaust manifold to cylinder head retaining nuts. 10. Remove the exhaust manifold, seals and gaskets. 11. Clean all sealing surfaces. INSTALLATION PROCEDURE 1. Install a new exhaust manifold gasket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3055 2. Install the exhaust manifold. 3. Install the exhaust manifold nuts. Tighten the nuts to 13 Nm (110 inch lbs.). 4. Raise and support the vehicle. 5. Install the heat shield. Tighten the bolts to 14 Nm (124 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3056 6. Install the exhaust manifold brace to exhaust manifold fasteners. a. Tighten the bolt to 56 Nm (41 ft. lbs.). b. Tighten the nuts to 26 Nm (19 ft. lbs.). 7. Install the manifold to the flex decoupler fasteners. Tighten the fasteners to 35 Nm (26 ft. lbs.). 8. Lower the vehicle. 9. Coat the threads of the 02S (Oxygen sensor) connector with anti-seize compound GM P/N 5613695 or equivalent. 10. Connect the 02S (Oxygen sensor) connector. 11. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Clearance Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Clearance > Page 3061 Exhaust Pipe: Specifications Tightening Flex Decoupler Joint to Manifold Nut ...................................................................................................................................................... 45 Nm (33 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Front Pipe Exhaust Pipe: Service and Repair Front Pipe CAUTION: When a flex decoupler joint is moved from the normal mounting position it is possible to over-flex and damage the joint. Always support the flex decoupler joint and pipe assembly to avoid over flexing. The flex decoupler joint is designed to flex a maximum of six degrees which is equivalent to the pipes connected to the joint moving no more than 1 inch for every 1 foot length of pipe, (if the pipe connected to the joint is 3 feet long, the end of the pipe could be moved a maximum of 3 inches). REMOVAL PROCEDURE 1. Raise and support vehicle. 2. Support three way catalytic converter. 3. Exhaust manifold pipe assembly from three way catalytic converter. 4. Exhaust manifold pipe assembly from exhaust manifold. 5. Exhaust manifold and three way catalytic converter seals. 6. Clean flange surfaces. INSTALLATION PROCEDURE 1. Exhaust manifold and three way catalytic converter seals. 2. Exhaust manifold pipe assembly to exhaust manifold. 3. Exhaust manifold pipe assembly to three way catalytic converter. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Front Pipe > Page 3064 Exhaust Pipe: Service and Repair Intermediate Pipe NOTE: When replacing the intermediate pipe on an originally equipped welded system, a service muffler will be needed. CAUTION: When a flex decoupler joint is moved from the normal mounting position it is possible to over-flex and damage the joint. Always support the flex decoupler joint and pipe assembly to avoid over-flexing. The flex decoupler joint is designed to flex a maximum of six degrees which is equivalent to the pipes connected to the joint moving no more than 1 inch for every 1 foot length of pipe, (if the pipe connected to the joint is 3 feet long, the end of the pipe could be moved a maximum of 3 inches) REMOVAL PROCEDURE 1. Raise and support vehicle. 2. Support three way catalytic converter. 3. Cut intermediate pipe at muffler. 4. Intermediate pipe from three way catalytic converter. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Front Pipe > Page 3065 5. Intermediate pipe from hanger. 6. Intermediate pipe. 7. Muffler from hangers. 8. Three way catalytic converter seal. 9. Clean flange surface. INSTALLATION PROCEDURE 1. Three way catalytic converter seal. 2. Intermediate pipe to hanger. 3. Intermediate pipe to three way catalytic converter. 4. Muffler to hangers. 5. Weld muffler to intermediate pipe. 6. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Muffler: Customer Interest Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 3074 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Muffler: All Technical Service Bulletins Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 3080 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3081 Muffler: Specifications Muffler Hanger to Frame ..................................................................................................................... ..................................................... 16 Nm (12 ft. lbs.) Muffler Hanger to Muffler Bolt .......................... ...................................................................................................................................... 16 Nm (12 ft. lbs.) Muffler Strap ................................................................................................................................ ............................................................ 16 Nm (12 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 3082 Muffler: Service and Repair REMOVAL PROCEDURE 1. Raise and support vehicle. 2. Cut intermediate pipe at muffler near weld. 3. Muffler from hangers. INSTALLATION PROCEDURE 1. Muffler to hangers. 2. Weld muffler to intermediate pipe. 3. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3094 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3095 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3096 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3097 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3098 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 3104 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3109 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3110 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3111 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3112 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 3113 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Engine Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter Engine Control Module: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 3122 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 3123 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 3124 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 3125 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 3126 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 3127 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 3128 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 676535 > Nov > 96 > PCM - New Identification Label Engine Control Module: All Technical Service Bulletins PCM - New Identification Label File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-35 Date: November, 1996 INFORMATION Subject: New PCM Identification Label Models: Late 1996 and All 1997 Passenger Cars with Powertrain Control Modules (PCM) PCM Label Effective March 7, 1996, all 1996-1/2 and 1997 model year passenger cars received a change to the identification label used on PCM's. Other than its appearance, these changes do not affect the service replacement procedure of PCM's. The illustration details the changes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 01-06-02-012 > Dec > 01 > Water Pump - Coolant Weepage Water Pump: All Technical Service Bulletins Water Pump - Coolant Weepage File In Section: 06 - Engine/Propulsion System Bulletin No.: 01-06-02-012 Date: December, 2001 TECHNICAL Subject: Water Pump Weep (Install Coolant Collector) Models: 1996-1998 Buick Skylark 1996-2002 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am 1996-2002 Pontiac Sunfire with 2.4L Engine (VIN T - RPO LD9) Condition Some owners may comment on leakage of a few drops of coolant after parking their vehicle. A technician may notice that the water pump may show a staining around the weep hole. Cause The occasional drop of coolant and the staining may be the evidence of normal coolant weepage. The weep hole prevents normal coolant weepage from accumulating around the bearing seal. For more information on this normal condition, refer to Corporate Bulletin Number 00-06-02-009. Correction Replacing the water pump for this normal weepage is likely to result in a repeat of the customer concern. To address customer concerns and promote customer satisfaction, a coolant collector has been developed to trap and absorb normal weepage of the pump. The coolant collector is a hinged, two-part collar that easily snaps around the neck of the water pump. Installing this new part is quick and effective and reduces unnecessary water pump replacement. The coolant collector has a limited capacity to absorb coolant. If diagnosis with a pressure test of the coolant system indicates a failed pump seal, or if the customer concern is for coolant consumption, installing the coolant collector will not correct the condition. Coolant Collector Installation 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information subsection of the applicable Service Manual. 2. Place the open hinged coolant collector around the narrow neck area of the water pump. Position the hinged portion towards the front of the vehicle. Close the coolant collector, ensuring the tongue enter the latch. Exert pressure to lock the coolant collector in place until an audible click is heard, which ensure retention. 3. Lower the vehicle. Parts Information The coolant collector is available as part of an updated water pump kit and is also available separately. Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 01-06-02-012 > Dec > 01 > Water Pump - Coolant Weepage > Page 3138 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 00-06-02-009 > Dec > 00 > Water Pump - Weep (Normal Condition) Water Pump: All Technical Service Bulletins Water Pump - Weep (Normal Condition) File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-02-009 Date: December, 2000 INFORMATION Subject: Water Pump Weep (Normal condition) Models: 1996-1998 Buick Skylark 1996-2001 Chevrolet Cavalier 1997-1999 Chevrolet Malibu 1996-1998 Oldsmobile Achieva 1999-2001 Oldsmobile Alero 1996-2001 Pontiac Grand Am, Sunfire with 2.4 L Engine (VIN T - RPO LD9) Many coolant pumps may show a staining around the weep hole. This staining may be the evidence of normal coolant weepage. The weep hole permits the seal to breathe, allowing for expansion and contraction of the fluid and air around the outside of the seal assembly. This area of the pump housing provides a drain path to keep the bearing assembly seal dry. The weep hole also allows vapor to clear from the area to prevent crystalline formation. The seal face load springs control a balance of the hydrodynamic film required to lubricate the seal. As the pump stops turning, the spring squeezes most of the coolant from between the faces. This is known as weepage and is normal for automotive seals. It is normal for a drop or two of coolant to appear at the weep hole. It is not necessary to replace the coolant pump for weepage if you are working on the front of the engine and you notice a drop or a stain. The best tip is to be sure your diagnosis and repair is driven by the customer's concern. Follow Service Manual diagnostics. If the customer is actually seeing drops of coolant on the driveway, and you suspect the coolant pump, confirm your diagnosis with a pressure test of the coolant system and replace the pump if necessary. Finally, any time the coolant pump is serviced, or any other service is performed that requires removing the timing chain on the 2.4 L engine, it is critical that the chain tensioner reset procedure is followed correctly. Use the Service Manual procedure to release the timing chain tensioner. If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 01-06-02-012 > Dec > 01 > Water Pump - Coolant Weepage > Page 3148 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3153 Engine Control Module: Specifications PCM Retainer Bolts ............................................................................................................................. ................................................. 8-12 Nm (6-9 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3154 RH Front Corner Behind Fascia Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3157 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3158 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3159 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3160 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 Engine Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3182 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3183 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3184 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3185 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3186 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3187 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3188 Engine Control Module: Connector Views Connector View Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3189 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3190 Specification Powertrain Control Module: C1 And C2 Pinout Description Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3191 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3192 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3193 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3194 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 2 Of 2) Connector View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3195 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3196 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3197 Specification ECM/PCM/VCM Pinout Voltage The OE manufacture does not provide an ECM/PCM/VCM connector voltage pinout chart for this vehicle, only a function description. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment Engine Control Module: Service Precautions Aftermarket (Add-on) Electrical and Vacuum Equipment Aftermarket (Add-On) Electrical and Vacuum Equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicle's electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Notice: Do not add on any Add-On vacuum operated equipment to this vehicle. Notice: Connect the Add-On electrical operated equipment to the vehicle's electrical system at the battery (power and ground). Add-On electrical equipment, even when installed to these strict guidelines, may still cause the Powertrain system to malfunction. This may also include equipment not connected to the vehicle's electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any Powertrain problem is to eliminate all Aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 3200 Engine Control Module: Service Precautions Electrostatic Discharge Damage CAUTION: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Electronic components used in the control systems are often designed in order to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage; therefore, it is important to use care when handling and testing electronic components. The control module is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the control module circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the control module circuits unless instructed. Only test these circuits with a digital voltmeter J 39200, while the control module connectors remain connected to the control module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 3201 Engine Control Module: Service Precautions Use of Circuit Testing Tools Do not use a test lamp in order to diagnose the Powertrain electrical systems unless specifically instructed by the diagnostic procedures. Use the Connector Test Adapter kit, J 35616 whenever diagnostic procedures call for probing any connectors. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) Engine Control Module: Description and Operation PCM Outputs (Qdsm & Odm) DESCRIPTION The Powertrain Control Module (PCM) controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface mounted Quad Driver Module (QDSM), which can independently control up to 4 outputs (PCM) terminals or Output driver Modules (ODMs) which can independently control up to 7 outputs. Not all outputs are always used. OPERATION Drivers are fault protected. If a relay or solenoid is shorted, having very low or zero resistance, or if the control side of the circuit is shorted to voltage, it would allow too much current flow into the PCM. The Driver senses this and the output is turned "OFF" or internal resistance increases to limit current flow and protect the PCM and the driver. The result is high output terminal voltage when it should be low. If the circuit from B+ to the component or if the component is open, or the control side of the circuit is shorted to ground, terminal voltage will be low. Either of these conditions is considered to be a driver fault. When and output is "ON," the terminal is grounded and its voltage will normally be low. When an output is "OFF," its terminal voltage normally will be high. QDSMs and ODMs also have a fault line to indicate the presence of a current fault to the PCM's central processor. A scan tool displays the status of the ODM fault lines as "0" = OK, "1" = Fault. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) > Page 3204 Engine Control Module: Description and Operation Powertrain Control Module (PCM) PURPOSE The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control OPERATION The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics A faulty PCM will be determined in the diagnostic tables. Before replacing the PCM, a re-programming procedure should not be attempted unless instructed. If the re-programming is unsuccessful a DTC P0602 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure Engine Control Module: Service and Repair Password Learn Procedure PASSWORD LEARN PROCEDURE In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the IPC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 3209 Engine Control Module: Service and Repair PCM/EEPROM Replacement/Programming Note: Clear DTCs from the PCM any time either the PCM is reprogramed or the EGR valve is replaced, or anytime the ignition switch is turned on with the EGR valve electrical connector disconnected. This is due to the auto zeroing funtion of the PCM on the EGR pintle. Notice: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM, EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. Removal Procedure Important: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to PCM (for example, battery cable, PCM Pigtail, PCM fuse, jumper cables, etc.). The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and horn. 5. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 3210 6. Slide the PCM and retainer(1) from PCM bracket (2). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 7. Disconnect the PCM electrical connectors (1). 8. Remove the retainer (1) from the PCM (2). Installation Procedure Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the faulty PCM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 3211 Important: Refer to the latest Techline Information on Re-Programming or Flashing procedures. 1. Slide the PCM (2) into the PCM retainer (1). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 2. Connect the PCM electrical connectors (1). 3. Slide the PCM and retainer (1) into the PCM bracket (2) slots. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 3212 4. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb. ft.). 5. Connect the horn electrical connector and horn. 6. Install the horn attaching bolt. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3223 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3250 Fuel Pump Relay: Service and Repair Fuel Pump Relay Removal Procedure 1. Remove the relay center cover. 2. Remove the Fuel Pump Relay. Installation Procedure 1. Install the Fuel Pump Relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: Customer Interest PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 3260 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 3261 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: All Technical Service Bulletins PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 3267 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 3268 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 73-83-09 > May > 97 > Cooling - Low Coolant Light On During Sustained Driving Radiator Surge Tank: All Technical Service Bulletins Cooling - Low Coolant Light On During Sustained Driving File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-83-09 Date: May, 1997 Subject: Low Engine Coolant Light On During Sustained Driving at Moderate to High Engine RPM (Replace Cooling System Surge Tank) Models: 1997 Chevrolet Cavalier 1997 Pontiac Sunfire Built from SOP through December 31, 1996 Condition Some owners may comment that the low engine coolant light will illuminate during sustained driving at moderate to high engine RPM. Cause The design of the baffles in the cooling system surge tank coupled with the engine coolant air bleed pipe allow high coolant flow. This may allow the coolant sensor cavity in the surge tank to have an inadequate supply of coolant during sustained driving at moderate to high engine RPM. This may cause the low coolant light to illuminate even if the system is properly filled. Correction Verify that the system is properly filled and free of leaks. If the condition is still present, replace the cooling system surge tank with the revised design (see below for P/N's). Refer to the 1997 Service Manual. Parts Information Old P/N New P/N Description 22600776 22605500 For Chevrolet Cavalier and Pontiac Sunfire Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J3250 Tank, Radiator Use published Coolant Surge - labor operation R&R; or Replace time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3279 Ignition Control Module: Specifications Module to Cover Screws ..................................................................................................................... ........................................................ 4 Nm (35 lb. in.) Housing to Cover Screws ................................ ............................................................................................................................................ 4 Nm (35 lb. in.) Ignition Control Module Assembly to Cam Housing Bolts ........................................................................................................................ 22 Nm (16 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 3282 Ignition Control Module: Connector Locations Left Rear Of Transaxle LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3283 Ignition Control Module: Diagrams Electronic Ignition Control Module: C1 And C2 Electronic Ignition Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3284 Ignition Control Module: Description and Operation The Ignition Control Module (ICM) receives the Ignition Control (IC) signals from the PCM which in turn triggers the corresponding ignition coils. Since the PCM controls spark timing and ignition control during crank and run, there is no bypass mode. The ICM is not repairable. When an ICM is replaced, transfer the remaining components to the new module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3285 Ignition Control Module: Service and Repair Ignition Control Module (ICM) Removal Procedure Tools Required J 36011 Spark Plug Removal Tool. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. Disconnect the negative battery cable. 2. Remove the accelerator and cruise control cables out of the hold down clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3286 3. Remove the fuel line retainer clip bolt. 4. Disconnect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3287 5. Remove the Ignition Coil and the Electronic Ignition Control Module (ICM) assembly to camshaft housing bolts. Notice: Spark plug boots often adhere to the spark plugs. Use tool J 36011 in order to remove by first twisting and then pulling upward on retainers. Reinstall the boots and the retainers on the ignition coil housing secondary terminals. The boots and the retainers must be in place on the ignition coil housing secondary terminals prior to the ignition coil and the electronic ignition control module assembly installation or ignition control system damage may result. 6. Remove the Ignition Coil and Electronic Ignition Control Module (ICM) assembly from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3288 7. Remove the housing to cover screws. Important: When removing the housing from the cover make sure the ground strap stays in place. 8. Disconnect the coil harness electrical connector from the Ignition Control Module. 9. Remove the housing from the cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3289 10. Remove the Ignition Control Module to cover screws. 11. Remove the Ignition Control Module from the cover. Installation Procedure Important: DO NOT wipe grease from the module or coil if the same module is to be replaced. If a new module is to be installed, a package of silicone grease will be included with it. Spread the grease on the metal face of the module and on the cover where the module seats. This grease is necessary for module cooling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3290 1. Install the Ignition Control Module to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the Ignition Control Module to cover screws. Tighten Tighten the screws to 4 Nm (35 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3291 3. Install the ground strap (if the ground strap is not already installed). 4. Connect the Ignition Coil(s) electrical connector to the Ignition Control Module. Important: When installing the housing to the cover make sure the ground strap stays in place. 5. Install the housing to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3292 6. Install the housing to cover screws. Tighten Tighten the housing to cover screws 4 Nm (35 lb in). 7. Install the spark plug boots and the retainers to the housing (if the spark plug boot and retainer is not already installed). 8. Install the Ignition Coil and Electronic Ignition Control Module assembly to the engine while carefully aligning the spark boots to the spark plug terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3293 9. Install the ignition coil and the electronic ignition control module assembly to camshaft housing bolts after coating the threads with Sealant LOCTITE GM 12346004 or equivalent. Tighten Tighten the bolts to 22 Nm (16 lb ft). Important: The ICM cover bolts must be installed with isolator washers with the rubber side facing down. 10. Connect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3294 11. Install the fuel line retainer clip bolt. 12. Install the accelerator and cruise control cables into the hold down clip. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3335 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3336 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3346 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3347 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3348 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3349 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3350 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3351 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3353 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3354 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3355 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3356 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3357 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3358 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3359 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3360 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3361 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3362 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3363 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3364 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3365 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3366 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3367 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3368 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3369 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3370 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3371 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Left Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 3376 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3377 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperatures produce a high resistance (100,000 ohms at -40°C/-40°F), while high temperatures cause low resistance (70 ohms at 130°C/266°F). The Powertrain Control Module (PCM) uses this signal to determine the engine coolant temperature. OPERATION The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the ECT sensor's resistance is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table will lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3378 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection A scan tool displays the engine temperature in degrees Celsius. After the engine is started, the temperature should rise steadily to about 90°C (194°F) then stabilize when the thermostat opens. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3379 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal Procedure Notice: Care must be taken when handling an Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. Installation Procedure 1. Coat only the threads with sealer. 2. Install the ECT sensor in the engine, fully driven, seated and not stripped. 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3383 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3402 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3403 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3404 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3405 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3406 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3417 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3418 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3423 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3424 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3425 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3426 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3427 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 3428 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 3429 Fuel Level Sensor: Description and Operation Purpose The Fuel Level Sensor is an important input to the Control Module for the enhanced evaporative system diagnostic. The fuel level information is needed for the Control Module to know the volume of the fuel tank. The fuel level affects the rate of charge in the air pressure in the EVAP system. Several of the Enhanced Evaporative System diagnostic sub-tests are dependent upon the correct fuel level information. Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gage. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 3430 Fuel Level Sensor: Testing and Inspection The PCM uses the fuel level input to determine the expected amount of vapor pressure or vacuum to expect within the fuel tank. The scan tool can displays fuel level in percent for diagnostic purposes. A DTC P0460 will be set if the PCM does not see a change in the fuel level after a certain time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 3431 Fuel Level Sensor: Service and Repair Removal Procedure 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Drain fuel tank. Refer to Draining Fuel Tank. 3. Remove the fuel tank. Refer to Fuel Tank. 4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. Installation Procedure 1. Fuel level sensor to modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. Refer to Fuel Sender Assembly. 4. Install the fuel tank. Refer to Fuel Tank. 5. Refill tank. 6. Inspect for fuel leaks through the following steps: 6.1. Turn the ignition to the ON position for two seconds 6.2. Turn the ignition to the OFF position for ten seconds. 6.3. Turn the ignition to the ON position 6.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Description The Fuel Tank Pressure sensor is a 3 wire strain gauge sensor much like that of the common MAP sensor. However, this sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. A three wire electrical harness connects it to the Control Module. The Control Module supplies a 5 volt reference voltage and ground to the sensor. The sensor sends a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measures 1.3 to 1.7 volts. Operation When the air pressure in the tank is 4.5 inches H2O (1.25 kPa), the sensor output voltage should measure 0.5 plus/minus 0.2 volts. When there is neither a vacuum or a pressure in the tank, the sensor voltage should be at 1.5 volts at 14 inches H2O (-3.75 kPa) the sensor output voltage should be 4.5 volts plus/minus 0.2 volts. When energized, the evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP canister to the engine. The normally closed valve is pulse width modulated by the Control Module in order to precisely control the vapor flow. The valve opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in the fuel tank and then closed in order to seal the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 3435 Fuel Tank Pressure Sensor: Testing and Inspection The scan tool displays fuel tank pressure in volts and inches of water per second. The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 3436 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Perform Fuel Pressure Relief Procedure. 3. Drain fuel tank. 4. Remove the fuel tank. Refer to Fuel Tank. 5. Remove the electrical connector from the fuel tank vapor pressure sensor. 6. Remove the fuel tank vapor pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank vapor pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank vapor pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3442 LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 Intake Air Temperature Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3477 Intake Air Temperature Sensor: Description and Operation OPERATION The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the Engine Coolant Temperature (ECT) sensor. Low temperature produces a high resistance (100,000 ohms at -40°C / -40°F) while high temperature causes low resistance (70 ohms at 130°C / 266°F). The Powertrain Control Module (PCM) supplies a 5 volt signal to the sensor through a resistor in the PCM and measures the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A failure in the IAT sensor circuit should set either a Diagnostic Trouble Code (DTC) P0112 or P0113. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3478 Intake Air Temperature Sensor: Testing and Inspection A scan tool displays the temperature of the air entering the engine, which should be close to ambient air temperature when engine is cold, and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 3479 Intake Air Temperature Sensor: Service and Repair Removal Procedure The Intake Air Temperature (IAT) sensor is installed in the air induction flex tube. Care must be taken when handling a IAT sensor to avoid damage. 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. Installation Procedure 1. Install the IAT sensor into air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls - Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 3484 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 3487 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 3488 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3492 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3493 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3494 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3495 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3496 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3497 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3498 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3499 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3500 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3501 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3502 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3503 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3506 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3507 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3508 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3509 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3510 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3511 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3512 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3513 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3514 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3522 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3523 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Attaching Screw ............................................................................................................. .................................................... 6.5 Nm (5.7 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3527 Manifold Pressure/Vacuum Sensor: Locations Front Right Of Engine Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3528 Manifold Pressure/Vacuum Sensor: Description and Operation MAP Sensor DESCRIPTION The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. OPERATION The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gage. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3529 Manifold Pressure/Vacuum Sensor: Testing and Inspection A scan tool displays manifold pressure in kPa and MAP sensor signal voltage. Low pressure (high vacuum) displays a low voltage while a high pressure (low vacuum) displays a high voltage. A failure in the MAP sensor circuit should set a DTC P0107 or P0108 and using the applicable table will lead to the cause of the problem. A DTC P0108 may be set if misfire or a rough or unstable idle exists. A DTC P0105 will set for a MAP sensor that intermittently sends a zero voltage signal to the PCM. MAP Sensor Output Check 2.4L can also be used to check the MAP sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3530 Manifold Pressure/Vacuum Sensor: Service and Repair Removal Procedure 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor attaching screws (1). 4. Remove the MAP sensor vacuum hose (2). Installation Procedure 1. Connect the vacuum hose (2). 2. Install the MAP sensor attaching screw (1). Tighten the attaching screw to 6.5 Nm (5.7 lb. in.). 3. Connect the MAP sensor electrical connector. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems Oxygen Sensor: Technical Service Bulletins Oxygen Sensor - Locations in Various Exhaust Systems File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 3538 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 3539 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 3540 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to misidentification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3541 Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 41 Nm (30 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Technical Service Bulletin Update File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3544 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3546 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to mis-identification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3547 Component Location Views Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3548 LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3549 LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3550 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3551 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 Post - Converter Heated Oxygen Sensor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) Oxygen Sensor: Description and Operation Oxygen Sensor (O2S 1) Purpose The Oxygen Sensor (02S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately .1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). This voltage can be measured with a scan tool. Operation By monitoring the voltage output of the 02S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low 02S 1 voltage = rich command - Rich mixture - high 02S 1 voltage = lean command The 02S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 3588 Oxygen Sensor: Description and Operation Heated Oxygen Sensor 2 (HO2S 2) Catalyst Monitor The Rear Heated Oxygen Sensor (HO2S 2)is used to monitor the oxygen storage capability of the catalytic converter. Similar to the 02S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to .9 volt (low oxygen - rich mixture). Unlike the 02S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 3589 Oxygen Sensor: Description and Operation Catalyst Monitor Diagnostic Operation The OBD II catalyst monitor diagnostic measures oxygen storage capacity. In order to do this, the heated sensors are installed before and after the Three-Way Catalyst (TWC). Voltage variations between the sensors allow the control module to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalyst's capacity to store and release oxygen generally degrades. The OBD II catalyst monitor diagnostic is based on an correlation between conversion efficiency and oxygen storage capacity. A good catalyst (e.g. 95% hydrocarbon conversion efficiency) shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor (HO2S). A degraded catalyst (65% hydrocarbon conversion) shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S 2 is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst; low oxygen storage capacity indicates a failing catalyst. The TWC, HO2S 2, and HO2S 3 must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the Post-Catalyst HO2S 3 Outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S Contamination ^ Alternate fuels Exhaust system leaks may cause the following results: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevents the TWC diagnostic from functioning properly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 3590 Oxygen Sensor: Description and Operation HO2S Heater The oxygen sensor heaters are required by catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) Oxygen Sensor: Testing and Inspection Oxygen Sensor (O2S 1) A scan tool has several parameters that indicate the state of the exhaust gases: O2S 1 voltage, Short Term (S. T.) fuel trim, and Long Term (L. T.) fuel trim. A problem in the O2S 1 circuit should set a DTC P0134 (open circuit), DTC P0131 (lean exhaust indication), or DTC P0132 (rich exhaust indication). A faulty or lazy sensor will set a DTC P0133 (slow response) or a DTC P1133 (insufficient switching). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) > Page 3593 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (H02S 2) The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when the activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement Oxygen Sensor: Service and Repair Oxygen (O2S) Sensor Replacement O2S Service Removal Procedure Notice: The 02S 1 uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the oxygen sensor. Important: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the 02S 1. Important: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). Notice: Excessive force may damage the threads in the exhaust pipe. 1. Turn the ignition switch OFF. 2. Disconnect the Oxygen Sensor 1 electrical connector (1). 3. Carefully remove the oxygen sensor (2). Installation Procedure Important: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the oxygen sensor (2) with anti-seize compound, if necessary. 2. Install the Oxygen Sensor (2). Tighten the 02S 1 41 Nm (30 lb. ft.). 3. Connect the Oxygen Sensor 1 electrical connector (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement > Page 3596 Oxygen Sensor: Service and Repair Catalyst Monitor (HO2S) Oxygen Sensors Removal Procedure Notice: The HO2S 2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the rear heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the rear heated oxygen sensor. Important: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the O2S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. Notice: Excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. Installation Procedure Important: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb. ft.). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3600 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3634 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3635 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3636 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3645 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3646 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3652 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 3653 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3665 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3666 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3667 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3668 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 3671 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 3672 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 3673 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits Vehicle Speed Sensor: Technical Service Bulletins Instruments - New Diagnostic Tables For VSS Circuits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-81-32 Date: May, 1997 SERVICE MANUAL UPDATE Subject: Section 8A - Electrical Diagnosis - New Diagnostic Tables for Vehicle Speed Sensor Signal Circuit Models: 1996-97 Buick Skylark 1996 Chevrolet Beretta, Corsica 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1997 Oldsmobile Cutlass 1996-97 Pontiac Grand Am, Sunfire This bulletin is being issued to add new diagnostic tables to Section 8A of the Service Manual. The tables included describe the diagnostic procedures for the diagnosis of the Vehicle Speed Sensor signal circuit from the Powertrain Control Module (PCM) to auxiliary devices. Please insert the included diagnostic tables into the Electrical Diagnosis Instrument Cluster section (Cell 80 J/L/N cars; Cell 81 L/N cars) of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3678 8A - 1 - 1 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3679 8A - 1 - 2 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3680 8A - 1 - 3 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3681 8A - 1 - 4 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3682 8A - 1 - 5 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3683 8A - 1 - 6 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3684 8A - 1 - 7 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3685 8A - 1 - 8 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3686 8A - 1 - 9 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3687 8A - 1 - 10 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3688 8A - 1 - 11 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3689 8A - 1 - 12 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3690 8A - 1 - 13 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3691 8A - 1 - 14 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3692 8A - 1 - 15 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3693 8A - 1 - 16 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3694 8A - 1 - 17 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3695 8A - 1 - 18 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3696 8A - 1 - 19 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3697 8A - 1 - 20 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3698 8A - 1 - 21 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3699 8A - 1 - 22 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3700 8A - 1 - 23 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3701 8A - 1 - 24 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3702 8A - 1 - 25 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3703 8A - 1 - 26 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3704 8A - 1 - 27 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 3705 8A - 1 - 28 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3706 Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3709 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3710 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3711 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3712 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3713 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3714 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3715 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3716 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3717 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3718 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3719 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3720 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3721 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3722 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3723 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3724 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3728 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3731 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3732 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3733 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3736 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3737 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3738 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3739 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3740 Vehicle Speed Sensor: Description and Operation Description The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Trans. for more information. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3741 Vehicle Speed Sensor: Testing and Inspection A scan tool km/h MPH display should closely match the speedometer reading with drive wheels turning. A malfunction in the Vehicle Speed Sensor ( VSS) circuit will set a DTC P0502. Refer to Automatic Trans. if a problem exists with the VSS. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 Vehicle Speed Sensor: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Vehicle speed sensor (VSS) lead from transaxle. 3. Speed sensor housing bolts and housing. 4. Speed sensor housing O-ring. INSTALL OR CONNECT 1. Speed sensor housing O-ring. - Lubricate with DEXRON III. 2. Speed sensor housing and bolts. 3. VSS lead to transaxle. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 3744 Vehicle Speed Sensor: Service and Repair Isuzu 76mm REMOVE OR DISCONNECT 1. Vehicle speed sensor (VSS) lead from the transaxle. 2. Bolt/screw and retainer. 3. VSS assembly. 4. O-ring. INSTALL OR CONNECT 1. VSS assembly with New O-ring. - Lubricate O-ring with Synchromesh Transaxle Fluid GM P/N 12345349. 2. VSS assembly. 3. Retainer and bolt/screw. Tighten Vehicle Speed Sensor to 9 N.m (80 lb. in.). 4. VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 3745 Vehicle Speed Sensor: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Raise and support-vehicle. 2. Electrical connector. 3. Bolt holding speed sensor. 4. Vehicle speed sensor from case extension. 5. O-ring from vehicle speed sensor. INSTALL OR CONNECT 1. O-ring onto vehicle speed sensor. 2. Vehicle speed sensor into case extension. 3. Bolt. Tighten Bolt to 11 N.m (97 lb. in.). 4. Electrical connector. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3778 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3779 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3780 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3781 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3788 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3791 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3792 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3793 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3794 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3795 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3796 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3797 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3798 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3822 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3823 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3824 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3829 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3830 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3834 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3836 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3837 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3838 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3839 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3840 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3841 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3842 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3843 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3844 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3845 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3846 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3864 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3865 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3869 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3898 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3899 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3902 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3903 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3904 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 3914 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 3915 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 3916 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 3926 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 3927 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 3928 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3934 Ignition Switch Lock Cylinder: Service and Repair Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 3939 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 3942 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 3943 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3958 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3959 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3960 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3964 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3977 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3978 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure > Page 3984 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3985 Fuel Pressure: Service Precautions CAUTION: The following procedures and conditions MUST be followed or parts and system damage could result. 1. Do not operate the fuel pump without fuel in the lines. 2. Torque all screw couple fittings and fasteners to the specified torque. 3. If a fastener needs to be replaced, use the correct part number fastener or a fastener of equal size and strength (or stronger) for that application. 4. Always use a backup wrench when loosening or tighting a screw couple fitting. 5. On fuel injected models do not depress the accelerator pedal while trying to start the car. 6. Handle all fuel injection related parts with care as they may easily be damaged. 7. Always use new gaskets or O-rings when installing fuel lines or injectors. 8. Lightly lubricate O-rings and flare connections with gasoline. Do NOT use engine oil, gear lubricant or brake fluid. 9. Take care not to nick or scratch any nylon fuel lines. If damaged, they must be replaced. 10. Always cover nylon fuel lines with a wet towel before using a torch near them. Never expose the vehicle to temperatures higher than 115°C (239° F) for more than one hour, or more than 90°C (194°F) for any extended period. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3986 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3987 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3988 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3989 Diagnostic Chart Gauge Hookups CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn the in-tank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION Number(s) below refer to the step number(s) on the Diagnostic Table. 2. To relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition switch is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gage should be 284-325 kPa (41-47 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that can not maintain a constant fuel pressure has a leak in one or more of the following areas: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3990 ^ The fuel pump check valve. ^ The fuel pump flex pipe. ^ The valve or valve seat within the fuel pressure regulator. ^ The fuel injector(s). 4. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector width will increase. NOTE: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. This can cause false indications by the scan tool. 7. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the Engine OFF. 11. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 12. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a faulty fuel pressure regulator. 15. A lean condition may result from the fuel pressure being below 284 kPa (41 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold), hesitation, poor driveability, lack of power, surging, and misfiring. 16. Restricting the fuel return pipe causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gage outlet hose is pinched. 22. Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. 24. The fuel pressure regulator filter screen is designed to trap any contaminants introduced during engine assembly. If the fuel pressure regulator screen is dirty, it can be removed with a small pick and discarded without potential harm to the fuel pressure regulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 3994 Air/Fuel Mixture: Adjustments The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: Customer Interest Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 4003 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: All Technical Service Bulletins Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 4009 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 4010 Idle Speed: By Symptom Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 4011 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 4012 Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 4013 For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 4014 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 4015 Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 4016 Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 4017 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Specifications Air Cleaner Fresh Air Duct/Hose: Specifications Resonator Upper Attaching Bolt .......................................................................................................... ....................................................... 7 Nm (61 lb. in.) Headlamp Assembly Retaining Screws ....................................................................................................................................................... 7 Nm (61 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct Air Cleaner Fresh Air Duct/Hose: Service and Repair Front Air Duct Removal Procedure 1. Remove the air cleaner outlet splash shield. 2. Remove the LH headlamp assembly retaining screws. 3. Remove the LH headlamp assembly. 4. Disconnect the LH headlamp electrical connector(s). 5. Remove the front air cleaner outlet duct upper push in retainer. 6. Remove the resonator front push in retainer. 7. Raise the vehicle. 8. Remove the LF tire and wheel. 9. Remove the LF wheel house panel. 10. Remove the front air cleaner outlet duct lower retaining screw. 11. Remove the front air cleaner outlet duct through headlamp assembly opening. 12. Remove the resonator rear push in retainer and upper attaching bolt. 13. Remove the resonator assembly through wheel house opening. Installation Procedure 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push in retainer and the upper attaching bolt. Tighten the Resonator upper attaching bolt to 7 Nm (61 lb. in.). 3. Install the front air cleaner outlet duct through the headlamp assembly opening. 4. Install the front air cleaner outlet duct lower retaining screw. 5. Install the LF wheel house panel. 6. Install the LF tire and wheel. 7. Lower the vehicle. 8. Install the resonator front push in retainer. 9. Install the front air cleaner outlet duct upper push in retainer. 10. Install the LH headlamp electrical connector(s). 11. Install the LH headlamp assembly retaining screws. Tighten the headlamp assembly retaining screws to 7 Nm (61 lb. in.). 12. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct > Page 4024 Air Cleaner Fresh Air Duct/Hose: Service and Repair Fresh Air Hose Removal Procedure 1. Remove the air cleaner outlet resonator mounting screws. 2. Disconnect the air cleaner outlet resonator clamp at throttle body. 3. Remove the air cleaner outlet duct from air cleaner outlet resonator and air cleaner assembly. 4. Disconnect the crankcase vent hose from the air cleaner outlet duct. 5. Remove the air cleaner outlet resonator. Installation Procedure Important: Be sure that the air cleaner outlet resonator seals to the throttle body. 1. Install the air cleaner outlet resonator to the throttle body. 2. Connect the crankcase vent hose to the air cleaner outlet duct. 3. Install the air cleaner outlet resonator mounting screws. Tighten: ^ Air cleaner outlet resonator mounting screws to 5-7 Nm 60-84 lb. in.). ^ Air cleaner outlet resonator clamp to 4-5 Nm 35-44 lb in). 4. Install the air cleaner outlet duct to the air cleaner outlet resonator and the air cleaner assembly. Tighten Air cleaner outlet duct clamps to 45 Nm (35-44 lb. in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4033 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4039 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4040 Air Filter Element: Specifications Air Cleaner Cover Screws ................................................................................................................... ........................................................ 3 Nm (26 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4041 Air Filter Element: Service and Repair Air Filter Removal Procedure 1. Remove the upper air cleaner screws. 2. Remove the air cleaner cover. 3. Remove the air cleaner filter from lower air cleaner housing. 4. Inspect the air cleaner filter for dust, dirt, and water. 5. Replace if required. Installation Procedure 1. Install the air cleaner filter into the lower air cleaner housing. 2. Install the air cleaner cover to air cleaner housing. 3. Install the air cleaner screws. Tighten the air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition - Revised Spark Plug Gap Spark Plug: Technical Service Bulletins Ignition - Revised Spark Plug Gap File In Section: 6E - Engine Fuel & Emission Bulletin No.: 77-65-11A Date: May, 1997 INFORMATION Subject: Production Spark Plug Gap Change Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN T - RPO LD9) This bulletin is being revised to add Chevrolet Malibu to models. Please discard Corporate Bulletin Number 77-65-11 (Section 6E - Engine Fuel & Emission). A change in spark plug gap has been made to reduce spark plug fouling during repeated low speed operation of these vehicles at assembly plants, rail heads and dealer/retailer unloading points. The electrode gap of the production spark plugs has been reduced from 1.52 mm (0.060 in) to 1.27 mm (0.050 in). If a spark plug is removed to perform a service procedure and the gap is found to be 1.52 mm (0.060 in) and the spark plugs are functioning normally, do not change the spark plugs. Original equipment spark plugs will have the production part number imprinted on the ceramic insulator. The 1.52 mm (0.060 in) electrode gap spark plug will have a production part number of 25164044 and the 1.27 mm (0.050 in) electrode gap spark plug will have a production part number of 25312636. The service spark plug part number for all 1997 LD9 engines is 25164048 with an electrode gap of 1.27 mm (0.050 in). Important: Do not mix spark plugs with different electrode gaps on the same engine. If it becomes necessary to change a spark plug in any of these vehicles equipped with spark plugs that have a 1.52 mm (0.060 in) gap, replace all four spark plugs with GM Part Number 25164048 with the electrode gap set at 1.27 mm (0.050 in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 4064 Spark Plug: Specifications Spark Plug Torque 13 lb. ft. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4065 Spark Plug: Application and ID Spark Plug Identification Chart Spark Plugs: GM Part # 24161677 A-C Type 41-928 Gapped @ 1.52mm (0.060 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4066 Spark Plug: Description and Operation NOTE: This engine has aluminum cylinder heads. Allow the engine to cool before removing spark plugs, or the spark plug threads in the cylinder head may be damaged. - This engine uses tapered seat resistor type spark plugs without gaskets. Always replace plugs with the same spark plug as listed. DESCRIPTION Normal service is assumed to be a mixture of idling, slow speed, and high speed driving. Occasional or intermittent highway driving is needed for good spark plug performance because it gives increased combustion heat that bums away any excess deposits of carbon or oxides that have built up from frequent idling or continual stop-and-go driving. Spark plugs are protected by an insulating boot made of special heat-resistant material which covers the spark plug terminal and extends downward over a portion of the plug insulator. These boots prevent flash-over which causes engine mis-firing. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of a high-tension field, and has no effect on ignition performance. Usually it can be detected only in darkness. This discharge may repel dust particles, leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Spark plugs must operate within certain temperature limits if they are to provide the performance and service life expected. The spark plug selected for an engine is based on the normal service which the engine was designed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4067 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4068 Spark Plug: Service and Repair CAUTION: To avoid engine damage, do not remove spark plugs when engine is warm. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Electronic ignition module assembly 4 bolts and connector. 3. Remove by pulling straight up on housing. 4. Use tool J 36011 or equivalent to remove connector assembly(s) if stuck to the spark plugs. - Use tool by first twisting then pulling up on the connector assembly. 5. Remove debris from area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. INSTALL OR CONNECT 1. Adjust spark plug gap to 1.52 mm (0.060 inch) using a round wire type spark plug gap gage. While gapping plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start spark plugs into the cylinder head. Tighten Spark plugs to 18 Nm (13 lbs. ft.). 3. Reinstall onto the module assembly any spark plug boot connector assembly that stuck to a spark plug. - Check to be sure spring terminal is inside boot. - Reapply dielectric lubricant to insulator boot. 4. Locate module assembly over spark plugs and push straight down. 5. Clean any loose lubricant that is present on the module assembly to cam housing bolts. 6. Apply threadlocker onto the module assembly to cam housing bolts. CAUTION: Hand start the module assembly to cam housing bolts. Tighten Bolts to 22 Nm (16 lbs. ft.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4069 7. Electrical connector. 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Intake Valve Cold Valve Lash ................................................................................................................................... 0.13 - 0.17 mm (0.005 - 0.007 inches) Exhaust Valve Cold Valve Leash .............................................................................................................................. 0.13 - 0.17 mm (0.005 - 0.007 inches) Intake Valve Hot Valve Leash ................................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Exhaust Valve Hot Valve Leash ............................................................................................................................... 0.17 - 0.21 mm (0.007 - 0.008 inches) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation A/C Signal: Description and Operation GENERAL DESCRIPTION The A/C compressor clutch is controlled by the Powertrain Control Module (PCM). This allows the PCM to manage idle quality, improve wide open throttle performance, and to protect the A/C system from excessively high and low pressures. The PCM controlled air conditioning system uses a variable displacement compressor referred to as a V-5 compressor. The V-5 compressor meets the A/C requirements without cycling. OPERATION The PCM controlled air conditioning system consists of an A/C compressor clutch relay, an A/C compressor clutch and an A/C refrigerant pressure sensor. The Instrument Panel Cluster (IPC) and the A/C select switch also have input the PCM through the UART serial data circuit. The A/C refrigerant pressure sensor is used to indicate high side pressures. The PCM uses this information to control the cooling fan operation, the A/C compressor clutch operation and the idle speed. A fault in the A/C refrigerant pressure sensor circuit will set a DTC P0530. This will cause the PCM to disable the A/C compressor clutch compressor. The PCM determines high and low pressures in the A/C system by the voltage signal it receives from the A/C refrigerant pressure sensor. This allows the PCM to protect the A/C system from excessively high and low pressures. If the A/C refrigerant pressure sensor voltage exceeds about 4.7V, indicating pressure of 428 psi, the PCM will disable the A/C compressor clutch. The A/C compressor clutch will remain disabled until the A/C refrigerant pressure sensor voltage falls below 1.98V, indicating about 170 psi. The PCM will temporarily disable the A/C compressor clutch during the following conditions: - A wide open throttle. - A high RPM. - High power steering loads. - Hot engine re-starts. - If the engine coolant temperature exceeds 125°C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accessory Signal > Component Information > Description and Operation Accessory Signal: Description and Operation GENERAL DESCRIPTION All front wheel drive vehicles with transversely mounted engines, use an electric cooling fan. The fan is used for engine coolant and A/C condenser cooling and only operates under certain conditions. OPERATION The electric cooling fan operates when engine cooling temperature exceeds a certain value. The cooling fan on this engine is totally controlled by the Powertrain Control Module (PCM). The cooling fan has one speed. The PCM turns the cooling fan ON by grounding the coil of the cooling fan relay when certain conditions are met. When A/C is requested, the cooling fan will also be turned ON. When vehicle speed is above 38 MPH, the PCM opens the ground to the cooling fan relay because there should be sufficient air moving through the radiator to cool the engine coolant. If A/C refrigerant pressure or engine coolant temperature becomes excessive or the Malfunction Indicator Lamp (MIL) is illuminated, the PCM will turn the fan ON regardless of vehicle speed. COOLING FAN RUN-ON The PCM usually powers down 10 to 30 seconds after the ignition is turned OFF. Since the cooling fan is PCM controlled, the PCM may remain powered up for up to 7 minutes after the ignition is turned OFF to provide a ground in order to energize the cooling fan relay. This is called a fan Run-On and will occur if any of the following combinations of conditions exist when the ignition is turned OFF. - Engine coolant temperature greater than 100°C (212°F) and intake air temperature greater than 80°C (176°F). - Engine coolant temperature greater than 112°C (234°F) and intake air temperature greater than 70°C (158°F). - Engine coolant temperature greater than 116°C (241°F). The PCM and cooling fan will remain ON until these combinations of conditions no longer exist, up to a maximum of 7 minutes. If the cooling fan is OFF when the PCM powers down, it will remain OFF regardless of any temperatures until the ignition is turned ON again. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4099 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4123 LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Intake Air Temperature Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4158 Intake Air Temperature Sensor: Description and Operation OPERATION The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the Engine Coolant Temperature (ECT) sensor. Low temperature produces a high resistance (100,000 ohms at -40°C / -40°F) while high temperature causes low resistance (70 ohms at 130°C / 266°F). The Powertrain Control Module (PCM) supplies a 5 volt signal to the sensor through a resistor in the PCM and measures the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A failure in the IAT sensor circuit should set either a Diagnostic Trouble Code (DTC) P0112 or P0113. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4159 Intake Air Temperature Sensor: Testing and Inspection A scan tool displays the temperature of the air entering the engine, which should be close to ambient air temperature when engine is cold, and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4160 Intake Air Temperature Sensor: Service and Repair Removal Procedure The Intake Air Temperature (IAT) sensor is installed in the air induction flex tube. Care must be taken when handling a IAT sensor to avoid damage. 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. Installation Procedure 1. Install the IAT sensor into air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4164 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4165 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4173 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4175 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4199 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4200 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Left Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 4205 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4206 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperatures produce a high resistance (100,000 ohms at -40°C/-40°F), while high temperatures cause low resistance (70 ohms at 130°C/266°F). The Powertrain Control Module (PCM) uses this signal to determine the engine coolant temperature. OPERATION The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the ECT sensor's resistance is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table will lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4207 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection A scan tool displays the engine temperature in degrees Celsius. After the engine is started, the temperature should rise steadily to about 90°C (194°F) then stabilize when the thermostat opens. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4208 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal Procedure Notice: Care must be taken when handling an Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. Installation Procedure 1. Coat only the threads with sealer. 2. Install the ECT sensor in the engine, fully driven, seated and not stripped. 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4212 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4216 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4246 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4247 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations Data Link Connector: Component Locations The Data Link Connector (DLC) is located on the driver's side, under the instrument panel and is sometimes covered by a plastic cover labeled "DIAGNOSTIC CONNECTOR." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations > Page 4252 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Data Link Connector: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 Data Link Connector: Connector Views Data Link Connector (DLC) Data Link Connector Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 Data Link Connector Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Data Link Connector: Electrical Diagrams Data Link Connector (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 Data Link Connector (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Circuit Operation Data Link Connector: Description and Operation Circuit Operation There are two data lines that can be accessed with a scan tool. The Serial Data Line UART (800 CKT) allows the scan tool (when connected), Powertrain Control Module, Instrument Panel Cluster, Sensing Diagnostic Module, and the Electronic Brake Control Module to communicate via serial data. The Serial Data Line Class 2 (1807 CKT) allows a scan tool to directly access the Powertrain Control Module to read emissions related information. A scan tool can gain access to both data lines through the Data Link Connector (DLC). System operations can then be monitored or controlled for diagnostic purposes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Circuit Operation > Page 4292 Data Link Connector: Description and Operation Data Link Connector (DLC) Data Link Connector (DLC) DESCRIPTION The provision for communicating with the control module is the Data Link Connector (DLC). It is usually located under the instrument panel. The DLC is used to connect to a scan tool. Some common uses of the scan tool are listed below: - Identifying stored Diagnostic Trouble Codes (DTCs). - Clearing DTCs - Performing output control tests. - Reading serial data. Class II Serial Data U.S. Federal regulations require that all automobile manufacturers establish a common communications system. General Motors utilizes the Class II communications system. Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by the transmission and reception of multiple signals over a single wire. The messages carried on Class II data streams are also prioritized. In other words, if two messages attempt to establish communications on the data line at the same time, only the message with higher priority will continue. The device with the lower priority message must wait. The most significant result of this regulation is that the regulation provides scan tool manufacturers with the capability of accessing data from any make or model vehicle sold in the United States. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4301 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4302 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4303 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4304 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4305 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4311 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4316 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4317 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4318 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4319 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4320 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Engine Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter Engine Control Module: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4329 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4330 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4331 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4332 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4333 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4334 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4335 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 676535 > Nov > 96 > PCM - New Identification Label Engine Control Module: All Technical Service Bulletins PCM - New Identification Label File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-35 Date: November, 1996 INFORMATION Subject: New PCM Identification Label Models: Late 1996 and All 1997 Passenger Cars with Powertrain Control Modules (PCM) PCM Label Effective March 7, 1996, all 1996-1/2 and 1997 model year passenger cars received a change to the identification label used on PCM's. Other than its appearance, these changes do not affect the service replacement procedure of PCM's. The illustration details the changes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4345 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Engine Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter Engine Control Module: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4354 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4355 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4356 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4357 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4358 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4359 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4360 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 676535 > Nov > 96 > PCM - New Identification Label Engine Control Module: All Technical Service Bulletins PCM - New Identification Label File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-35 Date: November, 1996 INFORMATION Subject: New PCM Identification Label Models: Late 1996 and All 1997 Passenger Cars with Powertrain Control Modules (PCM) PCM Label Effective March 7, 1996, all 1996-1/2 and 1997 model year passenger cars received a change to the identification label used on PCM's. Other than its appearance, these changes do not affect the service replacement procedure of PCM's. The illustration details the changes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4365 Engine Control Module: Specifications PCM Retainer Bolts ............................................................................................................................. ................................................. 8-12 Nm (6-9 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4366 RH Front Corner Behind Fascia Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 Engine Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 Engine Control Module: Connector Views Connector View Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 Specification Powertrain Control Module: C1 And C2 Pinout Description Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4404 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4405 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 2 Of 2) Connector View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 Specification ECM/PCM/VCM Pinout Voltage The OE manufacture does not provide an ECM/PCM/VCM connector voltage pinout chart for this vehicle, only a function description. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment Engine Control Module: Service Precautions Aftermarket (Add-on) Electrical and Vacuum Equipment Aftermarket (Add-On) Electrical and Vacuum Equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicle's electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Notice: Do not add on any Add-On vacuum operated equipment to this vehicle. Notice: Connect the Add-On electrical operated equipment to the vehicle's electrical system at the battery (power and ground). Add-On electrical equipment, even when installed to these strict guidelines, may still cause the Powertrain system to malfunction. This may also include equipment not connected to the vehicle's electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any Powertrain problem is to eliminate all Aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 4412 Engine Control Module: Service Precautions Electrostatic Discharge Damage CAUTION: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Electronic components used in the control systems are often designed in order to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage; therefore, it is important to use care when handling and testing electronic components. The control module is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the control module circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the control module circuits unless instructed. Only test these circuits with a digital voltmeter J 39200, while the control module connectors remain connected to the control module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 4413 Engine Control Module: Service Precautions Use of Circuit Testing Tools Do not use a test lamp in order to diagnose the Powertrain electrical systems unless specifically instructed by the diagnostic procedures. Use the Connector Test Adapter kit, J 35616 whenever diagnostic procedures call for probing any connectors. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) Engine Control Module: Description and Operation PCM Outputs (Qdsm & Odm) DESCRIPTION The Powertrain Control Module (PCM) controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface mounted Quad Driver Module (QDSM), which can independently control up to 4 outputs (PCM) terminals or Output driver Modules (ODMs) which can independently control up to 7 outputs. Not all outputs are always used. OPERATION Drivers are fault protected. If a relay or solenoid is shorted, having very low or zero resistance, or if the control side of the circuit is shorted to voltage, it would allow too much current flow into the PCM. The Driver senses this and the output is turned "OFF" or internal resistance increases to limit current flow and protect the PCM and the driver. The result is high output terminal voltage when it should be low. If the circuit from B+ to the component or if the component is open, or the control side of the circuit is shorted to ground, terminal voltage will be low. Either of these conditions is considered to be a driver fault. When and output is "ON," the terminal is grounded and its voltage will normally be low. When an output is "OFF," its terminal voltage normally will be high. QDSMs and ODMs also have a fault line to indicate the presence of a current fault to the PCM's central processor. A scan tool displays the status of the ODM fault lines as "0" = OK, "1" = Fault. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) > Page 4416 Engine Control Module: Description and Operation Powertrain Control Module (PCM) PURPOSE The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control OPERATION The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics A faulty PCM will be determined in the diagnostic tables. Before replacing the PCM, a re-programming procedure should not be attempted unless instructed. If the re-programming is unsuccessful a DTC P0602 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure Engine Control Module: Service and Repair Password Learn Procedure PASSWORD LEARN PROCEDURE In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the IPC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4421 Engine Control Module: Service and Repair PCM/EEPROM Replacement/Programming Note: Clear DTCs from the PCM any time either the PCM is reprogramed or the EGR valve is replaced, or anytime the ignition switch is turned on with the EGR valve electrical connector disconnected. This is due to the auto zeroing funtion of the PCM on the EGR pintle. Notice: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM, EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. Removal Procedure Important: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to PCM (for example, battery cable, PCM Pigtail, PCM fuse, jumper cables, etc.). The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and horn. 5. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4422 6. Slide the PCM and retainer(1) from PCM bracket (2). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 7. Disconnect the PCM electrical connectors (1). 8. Remove the retainer (1) from the PCM (2). Installation Procedure Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the faulty PCM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4423 Important: Refer to the latest Techline Information on Re-Programming or Flashing procedures. 1. Slide the PCM (2) into the PCM retainer (1). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 2. Connect the PCM electrical connectors (1). 3. Slide the PCM and retainer (1) into the PCM bracket (2) slots. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4424 4. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb. ft.). 5. Connect the horn electrical connector and horn. 6. Install the horn attaching bolt. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4429 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4430 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4431 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4432 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4433 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4434 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4435 Fuel Level Sensor: Description and Operation Purpose The Fuel Level Sensor is an important input to the Control Module for the enhanced evaporative system diagnostic. The fuel level information is needed for the Control Module to know the volume of the fuel tank. The fuel level affects the rate of charge in the air pressure in the EVAP system. Several of the Enhanced Evaporative System diagnostic sub-tests are dependent upon the correct fuel level information. Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gage. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4436 Fuel Level Sensor: Testing and Inspection The PCM uses the fuel level input to determine the expected amount of vapor pressure or vacuum to expect within the fuel tank. The scan tool can displays fuel level in percent for diagnostic purposes. A DTC P0460 will be set if the PCM does not see a change in the fuel level after a certain time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4437 Fuel Level Sensor: Service and Repair Removal Procedure 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Drain fuel tank. Refer to Draining Fuel Tank. 3. Remove the fuel tank. Refer to Fuel Tank. 4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. Installation Procedure 1. Fuel level sensor to modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. Refer to Fuel Sender Assembly. 4. Install the fuel tank. Refer to Fuel Tank. 5. Refill tank. 6. Inspect for fuel leaks through the following steps: 6.1. Turn the ignition to the ON position for two seconds 6.2. Turn the ignition to the OFF position for ten seconds. 6.3. Turn the ignition to the ON position 6.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Description The Fuel Tank Pressure sensor is a 3 wire strain gauge sensor much like that of the common MAP sensor. However, this sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. A three wire electrical harness connects it to the Control Module. The Control Module supplies a 5 volt reference voltage and ground to the sensor. The sensor sends a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measures 1.3 to 1.7 volts. Operation When the air pressure in the tank is 4.5 inches H2O (1.25 kPa), the sensor output voltage should measure 0.5 plus/minus 0.2 volts. When there is neither a vacuum or a pressure in the tank, the sensor voltage should be at 1.5 volts at 14 inches H2O (-3.75 kPa) the sensor output voltage should be 4.5 volts plus/minus 0.2 volts. When energized, the evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP canister to the engine. The normally closed valve is pulse width modulated by the Control Module in order to precisely control the vapor flow. The valve opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in the fuel tank and then closed in order to seal the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4441 Fuel Tank Pressure Sensor: Testing and Inspection The scan tool displays fuel tank pressure in volts and inches of water per second. The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4442 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Perform Fuel Pressure Relief Procedure. 3. Drain fuel tank. 4. Remove the fuel tank. Refer to Fuel Tank. 5. Remove the electrical connector from the fuel tank vapor pressure sensor. 6. Remove the fuel tank vapor pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank vapor pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank vapor pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Valve Attaching Screws ................................................................................................................ .................................................... 3.0 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 4446 Idle Speed/Throttle Actuator - Electronic: Locations Front Right Of Engine Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 4447 Motor Idle Air Control Valve Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 4448 Idle Speed/Throttle Actuator - Electronic: Description and Operation Purpose The throttle body (1) assembly is attached to the intake manifold. The throttle body is used to control air flow into the engine, thereby controlling engine output. The throttle valve within the throttle body is opened by the driver through the accelerator controls. During engine idle, the throttle valve is almost closed, and air flow control is handled by the Idle Air Control (IAC) (3) .The throttle body also provides the location for mounting the Throttle Position ( TP) (2) sensor and provides a manifold vacuum source for various components. Vacuum ports are located at the throttle valve to generate vacuum signals needed by various components. Operation Engine idle speed is controlled by the PCM through the IAC valve (1) mounted on the throttle body. The PCM sends voltage pulses to the IAC valve motor windings causing the IAC valve pintle (3) to move IN (toward the seat) or OUT (away from the seat) a given distance (a step or count) for each pulse. The commanded location (steps away from the seated position) can be observed as a number of counts displayed on a scan tool. The pintle movement controls the airflow around the throttle valve (2), which in turn, controls engine idle speed: Pintle Extended=Decrease RPM=Lower Counts. Pintle Retracted=Increase RPM=Higher Counts. The controlled or desired idle speed for all engine operating conditions is programmed into the EEPROM of the PCM. The programmed engine speeds are based on coolant temperature, park/neutral switch status, vehicle speed, battery voltage, and A/C refrigerant pressure (if equipped). The PCM learns the proper IAC valve positions to achieve warm, stabilized idle speeds (RPM), desired for the various conditions (P/N or Drive, A/C ON or OFF, if equipped). This information is stored in PCM Keep Alive memories (information is retained after ignition is OFF). All other IAC valve positioning is calculated based on these memory values. As a result, engine variations due to wear, and variations in minimum throttle valve position (within limits) do not affect engine idle speeds. This system provides correct idle control under all conditions. This also means that disconnecting power to the PCM can result in incorrect idle control or the necessity to partially depress the accelerator when starting, until the PCM relearns idle control. ^ Engine idle speed is a function of total airflow into the engine based on IAC valve pintle position plus throttle valve opening plus calibrated vacuum loss through accessories. ^ The minimum throttle valve position is set at the factory with a stop screw. This setting allows enough air flow by the closed throttle valve to cause the IAC valve pintle to be positioned a calibrated number of steps (counts) from the seat during controlled idle operation. The minimum throttle valve position for this engine is not the same as the minimum idle speed associated with other fuel injected engines. The throttle stop screw is filled at the factory following an adjustment. Important: Do Not try to remove the filler and readjust the stop screw. Misadjustment may set a DTC P0506 or a DTC P0507. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 4449 Idle Speed/Throttle Actuator - Electronic: Service and Repair Removal Procedure 1. Remove the IAC valve electrical connector. 2. Remove the IAC valve attaching screws (1). Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. 3. Remove the IAC valve assembly (2). ^ Clean IAC valve O-ring sealing surface, pintle valve seat, and air passage. ^ The IAC valve may be cleaned, using GM cleaner 1052626 or GM X-66A. Use a shop towel or parts cleaning brush to remove heavy deposits. ^ Shiny spots on the pintle or seat are normal, and do not indicate misalignment or a bent pintle shaft. ^ Whenever air passage have heavy deposits, remove throttle body for complete cleaning. ^ Inspect IAC valve O-ring for cuts, cracks, or distortion. Replace if damaged. ^ Whenever installing a new IAC valve, be sure to replace it with an identical part. IAC valve pintle shape and diameter are designed for the specific application. Installation Procedure 1. Lubricate IAC valve O-ring (3) with clean engine oil. 2. Install the IAC valve assembly (2). 3. Install the IAC valve attaching screws (1). Tighten the IAC valve attaching screws to 3.0 Nm (27 lb. in.). 4. Install the electrical connector. 5. Install the reset IAC valve pintle position: 5.1. Turn ignition switch to the ON position (engine OFF). 5.2. Turn ignition OFF for ten seconds. 5.3. Start engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Ignition Output Signal > Component Information > Description and Operation Ignition Output Signal: Description and Operation This system uses the same circuits between the ICM and the PCM that distributor type systems use. Following is a brief description for each of the IC circuits. Crankshaft Position (CKP) Sensor Activity (7X reference) The CKP sensor generates a signal to the ICM which results in a reference pulse (square wave signal) being sent to the PCM. The PCM uses this signal to calculate crankshaft position, engine speed and injector pulse width. The engine will not start or run if this circuit is open or grounded. Reference Low This wire is grounded through the ICM and insures that the ground circuit has no voltage drop between the ICM and the PCM which could affect performance. The PCM compares voltage pulses on the 7X or reference input to those on this circuit, ignoring any pulses that appear on both. A pulse that appears on the reference low circuit is assumed to be caused by Radio Frequency Interference (RFI). Ignition Control (IC) 1 & 2 The PCM sends the ignition control pulse to the ICM on these circuits. These signals are similar to the 7X reference pulse square wave except that the PCM uses sensor inputs to determine the pulse timing to control spark advance. When the PCM receives the 7X signal, it will determine which pair of cylinders will be fired (1 & 4 or 2 & 3). It then tells the ICM which cylinder to fire through the ignition control circuits. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Circuit Operation Information Bus: Description and Operation Circuit Operation There are two data lines that can be accessed with a scan tool. The Serial Data Line UART (800 CKT) allows the scan tool (when connected), Powertrain Control Module, Instrument Panel Cluster, Sensing Diagnostic Module, and the Electronic Brake Control Module to communicate via serial data. The Serial Data Line Class 2 (1807 CKT) allows a scan tool to directly access the Powertrain Control Module to read emissions related information. A scan tool can gain access to both data lines through the Data Link Connector (DLC). System operations can then be monitored or controlled for diagnostic purposes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Circuit Operation > Page 4457 Information Bus: Description and Operation Serial Data Communications Decimal/Hexadecimal/Binary Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Circuit Operation > Page 4458 Decimal/Hexadecimal/Binary Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Circuit Operation > Page 4459 Decimal/Hexadecimal/Binary Conversion Table UART SERIAL DATA Beginning in 1995 two methods of data transmission will be used. One method involves a Universally Asynchronous Receiving/Transmitting (UART) protocol. UART is an interfacing device that allows the on board computer to send and receive serial data. "Serial data" refers to information which is transferred in a linear fashion - over a single line, one bit at a time. A "data bus" describes the electronic pathway through which serial data travels. The UART receives data in a serial format, converts the data to parallel format, and places them on the data bus (which is recognizable to the on board computer). The UART also accepts parallel data from the data bus, converts the data to serial format, and transmits them to the Tech 1 or other scan tool. This method has been the common strategy for establishing a communication link between the on board control module and the off board monitor/scanner since 1981. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Circuit Operation > Page 4460 CLASS II SERIAL DATA U.S. Federal regulations require that all automobile manufacturers establish a common communications system. General Motors utilizes the "Class II" communications system. Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by the transmission and reception of multiple signals over a single wire. The messages carried on Class II data streams are also prioritized. In other words, if two messages attempt to establish communications on the data line at the same time, only the message with higher priority will continue. The device with the lower priority message must wait. The most significant result of this regulation is that it provides scan tool manufacturers with the capability of accessing data from any make or model vehicle sold in the United States. The data displayed on the Tech 1, Tech 2 or other scan tool will appear the same, with some exceptions. Some scan tools will only be able to display certain vehicle parameters as values that are a coded representation of the true or actual value. For more information on this system of coding, refer to decimal/binary/hexadecimal conversions table. On GM automobiles, the Tech 1 and Tech 2 display the actual values for vehicle parameters. It will not be necessary to perform any conversions from coded values to actual values. DECIMAL/BINARY/HEXADECIMAL CONVERSIONS Beginning in 1996, Federal Regulations require that all auto manufacturers selling vehicles in the United States provide scan tool manufacturers with software information to display vehicle operating parameters. All scan tool manufacturers will display a variety of vehicle information which will aid in repairing the vehicle. Some scan tools will display encoded messages which will aid in determining the nature of the concern. This method of encoding involves the use of a two additional numbering systems: Binary and Hexadecimal. The binary number system has a base of two numbers. Each digit is either a 0 or a 1. A binary number is an eight digit number and is read from right to left. Each digit has a position number with the farthest right being the 0 position and the farthest left being the 7 position. The 0 position, when displayed by a 1, indicates 1 in decimal. Each position to the left is double the previous position and added to any other position values marked as a 1. Refer to the Decimal/Hexadecimal/Binary conversion table when using scan tools that display encoded messages. The hexadecimal system is composed of 16 different alpha numeric characters. The alpha numeric characters used are numbers 0 through 9 and letters A through F. Refer to the Decimal/Hexadecimal/Binary conversion table when using scan tools that display encoded messages. The hexadecimal system is the most natural and common approach for scan tool manufacturers to display data represented by binary numbers and digital code. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview System Check Troubleshooting Hints PERFORM BEFORE BEGINNING SYSTEM DIAGNOSIS: SERIAL DATA LINE (UART) 1. If all components are not accessible with a scan tool, check for an open in CKT 800 between DLC terminal "9" and S277 or short to BATT or Ground. 2. If a single component is not accessible with a scan tool, check for an open in CKT 800. If the wire is OK, refer to Antilock Brake System ABS diagnosis, and to Air Bags (Supplemental Restraint Systems) for Supplemental Air Restraint diagnosis, and Instrument Panel, Gauges and Warning Indicators for Instrument Cluster diagnosis. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems See: Restraint Systems/Air Bag Systems See: Instrument Panel, Gauges and Warning Indicators SERIAL DATA LINE (CLASS 2) 1. If Powertrain Control Module (PCM) is not accessible with a scan tool, check for an open in CKT 1807. If the wire is OK, refer Powertrain Control Module Diagnosis. ^ Check for a broken (or partially broken) wire inside of the insulation which could cause system failure but prove "GOOD" in a continuity/voltage check (refer to "General Troubleshooting Procedures,"). See: Diagrams/Diagnostic Aids ^ Check for proper installation of aftermarket electronic equipment which may affect the integrity of other systems (refer to "General Troubleshooting Procedures,"). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4463 Information Bus: Symptom Related Diagnostic Procedures Chart #1 Scan Tool Can't Communicate W/One/More Modules On A Serial Data Bus (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4464 Chart #1 Scan Tool Can't Communicate W/One/More Modules On A Serial Data Bus (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4465 Chart #1 Scan Tool Can't Communicate W/One/More Modules On A Serial Data Bus (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4466 Chart #1 Scan Tool Can't Communicate W/One/More Modules On A Serial Data Bus (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4467 Symptom Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4468 Information Bus: Component Tests and General Diagnostics There are two data lines that can be accessed with a scan tool. The Serial Data Line UART (800 CKT) allows the scan tool (when connected), Powertrain Control Module, Instrument Panel Cluster, Sensing Diagnostic Module, and the Electronic Brake Control Module to communicate via serial data. The Serial Data Line Class 2 (1807 CKT) allows a scan tool to directly access the Powertrain Control Module to read emissions related information. A scan tool can gain access to both data lines through the Data Link Connector (DLC). System operations can then be monitored or controlled for diagnostic purposes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls - Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 4473 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 4476 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 4477 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4486 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4489 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4511 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4512 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation The CHECK ENGINE (Malfunction Indicator Lamp) Indicator in the Instrument Panel Cluster. The CHECK ENGINE Indicator will illuminate with the Ignition Switch in "RUN" position and engine off. The light will stay on a short time after the engine starts and should go out in 1 to 5 seconds. If the light stays on, or comes on while driving, service to the emission control system may be required. The indicator is controlled via a hardwired connection with the PCM and the IPC. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Attaching Screw ............................................................................................................. .................................................... 6.5 Nm (5.7 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4519 Manifold Pressure/Vacuum Sensor: Locations Front Right Of Engine Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4520 Manifold Pressure/Vacuum Sensor: Description and Operation MAP Sensor DESCRIPTION The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. OPERATION The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gage. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4521 Manifold Pressure/Vacuum Sensor: Testing and Inspection A scan tool displays manifold pressure in kPa and MAP sensor signal voltage. Low pressure (high vacuum) displays a low voltage while a high pressure (low vacuum) displays a high voltage. A failure in the MAP sensor circuit should set a DTC P0107 or P0108 and using the applicable table will lead to the cause of the problem. A DTC P0108 may be set if misfire or a rough or unstable idle exists. A DTC P0105 will set for a MAP sensor that intermittently sends a zero voltage signal to the PCM. MAP Sensor Output Check 2.4L can also be used to check the MAP sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4522 Manifold Pressure/Vacuum Sensor: Service and Repair Removal Procedure 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor attaching screws (1). 4. Remove the MAP sensor vacuum hose (2). Installation Procedure 1. Connect the vacuum hose (2). 2. Install the MAP sensor attaching screw (1). Tighten the attaching screw to 6.5 Nm (5.7 lb. in.). 3. Connect the MAP sensor electrical connector. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems Oxygen Sensor: Technical Service Bulletins Oxygen Sensor - Locations in Various Exhaust Systems File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 4530 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 4531 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 4532 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to misidentification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 4533 Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 41 Nm (30 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Technical Service Bulletin Update File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4536 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4537 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4538 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to mis-identification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4539 Component Location Views Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4540 LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4541 LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4542 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4543 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Post - Converter Heated Oxygen Sensor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) Oxygen Sensor: Description and Operation Oxygen Sensor (O2S 1) Purpose The Oxygen Sensor (02S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately .1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). This voltage can be measured with a scan tool. Operation By monitoring the voltage output of the 02S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low 02S 1 voltage = rich command - Rich mixture - high 02S 1 voltage = lean command The 02S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 4580 Oxygen Sensor: Description and Operation Heated Oxygen Sensor 2 (HO2S 2) Catalyst Monitor The Rear Heated Oxygen Sensor (HO2S 2)is used to monitor the oxygen storage capability of the catalytic converter. Similar to the 02S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to .9 volt (low oxygen - rich mixture). Unlike the 02S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 4581 Oxygen Sensor: Description and Operation Catalyst Monitor Diagnostic Operation The OBD II catalyst monitor diagnostic measures oxygen storage capacity. In order to do this, the heated sensors are installed before and after the Three-Way Catalyst (TWC). Voltage variations between the sensors allow the control module to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalyst's capacity to store and release oxygen generally degrades. The OBD II catalyst monitor diagnostic is based on an correlation between conversion efficiency and oxygen storage capacity. A good catalyst (e.g. 95% hydrocarbon conversion efficiency) shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor (HO2S). A degraded catalyst (65% hydrocarbon conversion) shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S 2 is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst; low oxygen storage capacity indicates a failing catalyst. The TWC, HO2S 2, and HO2S 3 must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the Post-Catalyst HO2S 3 Outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S Contamination ^ Alternate fuels Exhaust system leaks may cause the following results: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevents the TWC diagnostic from functioning properly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 4582 Oxygen Sensor: Description and Operation HO2S Heater The oxygen sensor heaters are required by catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) Oxygen Sensor: Testing and Inspection Oxygen Sensor (O2S 1) A scan tool has several parameters that indicate the state of the exhaust gases: O2S 1 voltage, Short Term (S. T.) fuel trim, and Long Term (L. T.) fuel trim. A problem in the O2S 1 circuit should set a DTC P0134 (open circuit), DTC P0131 (lean exhaust indication), or DTC P0132 (rich exhaust indication). A faulty or lazy sensor will set a DTC P0133 (slow response) or a DTC P1133 (insufficient switching). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) > Page 4585 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (H02S 2) The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when the activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement Oxygen Sensor: Service and Repair Oxygen (O2S) Sensor Replacement O2S Service Removal Procedure Notice: The 02S 1 uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the oxygen sensor. Important: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the 02S 1. Important: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). Notice: Excessive force may damage the threads in the exhaust pipe. 1. Turn the ignition switch OFF. 2. Disconnect the Oxygen Sensor 1 electrical connector (1). 3. Carefully remove the oxygen sensor (2). Installation Procedure Important: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the oxygen sensor (2) with anti-seize compound, if necessary. 2. Install the Oxygen Sensor (2). Tighten the 02S 1 41 Nm (30 lb. ft.). 3. Connect the Oxygen Sensor 1 electrical connector (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement > Page 4588 Oxygen Sensor: Service and Repair Catalyst Monitor (HO2S) Oxygen Sensors Removal Procedure Notice: The HO2S 2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the rear heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the rear heated oxygen sensor. Important: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the O2S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. Notice: Excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. Installation Procedure Important: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb. ft.). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: Recalls Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4598 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4599 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4600 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4601 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4602 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4608 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM Engine Control Module: All Technical Service Bulletins Recall - Corrosion/Moisture Entering the PCM Product Emission 99090 - PCM Corrosion/Moisture Intrusion #99090 99090--PCM Corrosion/Moisture Intrusion (Install Protective PCM Shield/Cover Assembly) Certain 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires Located in Fifteen U.S. High Road Salt Corrosion States (CT, IL, IN, MA, ME, MN, NH, NJ, NY, OH, PA, RI, VT, and WI) and in Ontario, Quebec and Atlantic Provinces, and Certain 1995, 1996, 1997, 1998 and 1999 Chevrolet Cavaliers and Pontiac Sunfires located in Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. Correction Dealers are to seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4613 Vehicles Involved Involved are certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories built within the following VIN breakpoints: Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) of GM Access Screen (Canada only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listing containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. These dealers listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces countries. Accordingly, you are urged to limit the use of this listing tot he follow-up necessary to complete this campaign. Parts Information Important An initial supply of covers and shields required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will occur the week of May 8, 2000. Pre-shipped parts will be charged to dealer's open parts account. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4614 Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to you "involved vehicles listing" prior to ordering requirements Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure 1. Disconnect the negative battery cable. 2. Remove the right-hand engine splash shield (in front of the right front tire assembly) 3. Remove the horn attachment bolt. Disconnect the wire and remove the horn. 4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM and the retainer from the PCM bracket. 5. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward. 6. Install the PCM into the vehicle bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4615 7. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Removing the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield. 8. Install the push-in retainer, P/N 10121502. through the lower front hole of the PCM shield and then through the side hold of the PCM cover. 9. Install the Campaign Identification Label. Campaign Identification Label For US Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering. Campaign Identification Label For CANADA Place the Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Put the Campaign Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering. Claim Information Submit a Product Campaign Claim with the information indicated. Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submissions. Customer Notification For US and CANADA Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4616 Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Campaign Responsibility For US and CANADA All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or owner, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make required correction according tot he instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle. May, 2000 Dear Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle. Reason For This Recall General Motors has decided that certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. What Will Be Done To prevent this condition from occurring, your GM dealer will seal the Powertrain Control Module (PCM) in a protective shield/cover assembly. This service will be performed for you at no charge. Contacting Your Dealer Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed. Customer Replay Card The attached customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completeing the reply card and returning it to us in the postage pad envelope. Courtesy Transportation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99090 > May > 00 > Recall - Corrosion/Moisture Entering the PCM > Page 4617 Your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. Emission Law Information In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. (Chevrolet, Pontiac-GMC) Division Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Engine Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter Engine Control Module: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4626 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4627 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4628 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4629 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4630 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4631 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4632 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 676535 > Nov > 96 > PCM - New Identification Label Engine Control Module: All Technical Service Bulletins PCM - New Identification Label File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-35 Date: November, 1996 INFORMATION Subject: New PCM Identification Label Models: Late 1996 and All 1997 Passenger Cars with Powertrain Control Modules (PCM) PCM Label Effective March 7, 1996, all 1996-1/2 and 1997 model year passenger cars received a change to the identification label used on PCM's. Other than its appearance, these changes do not affect the service replacement procedure of PCM's. The illustration details the changes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Engine Controls - Aftermarket Accessory Usage > Page 4642 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 83-81-32 > Sep > 98 > PCM Connector - Information on New Service Kits Engine Control Module: All Technical Service Bulletins PCM Connector - Information on New Service Kits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-32 Date: September, 1998 INFORMATION Subject: New Powertrain Control Module (PCM) Connector Service Kits Models: 1996-99 All Passenger Cars except Geo and Catera Two new kits have been released to service the Powertrain Control Module (PCM) connector If the connector has been damaged during servicing. This PCM has an aluminum body and is usually mounted underhood. Kit (P/N 12167308) contains the 80 way connector body, the cover, two each of four different terminal retainers and 25 empty cavity plugs. No terminals are included. If terminals are needed, use P/N 12084913 for 0.35 mm and 0.50 mm wire and P/N 12084912 for 0.80 mm wire. These terminals are included in the terminal repair kit J 38125A or B, and replacements can be ordered from Kent-Moore. kit (P/N 12167313) contains one connector seal. Whenever the connector is unbolted from the aluminum body of the PCM, the seal can stick to the body, or may be twisted. This seal should be replaced whenever the connector is removed in service. Parts Information P/N Description 12167308 Kit, PCM Harness Repair 12167313 Seal Kit, PCM Connector 12084912 Terminal 12084913 Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter Engine Control Module: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4651 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4652 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4653 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4654 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4655 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4656 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 4657 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 676535 > Nov > 96 > PCM - New Identification Label Engine Control Module: All Technical Service Bulletins PCM - New Identification Label File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-35 Date: November, 1996 INFORMATION Subject: New PCM Identification Label Models: Late 1996 and All 1997 Passenger Cars with Powertrain Control Modules (PCM) PCM Label Effective March 7, 1996, all 1996-1/2 and 1997 model year passenger cars received a change to the identification label used on PCM's. Other than its appearance, these changes do not affect the service replacement procedure of PCM's. The illustration details the changes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4662 Engine Control Module: Specifications PCM Retainer Bolts ............................................................................................................................. ................................................. 8-12 Nm (6-9 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4663 RH Front Corner Behind Fascia Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 Engine Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Engine Control Module: Connector Views Connector View Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Specification Powertrain Control Module: C1 And C2 Pinout Description Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Powertrain Control Module: C1 (Unused Cavities Are Not Shown) (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Powertrain Control Module: C2 (Unused Cavities Are Not Shown) (Part 2 Of 2) Connector View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Specification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Specification ECM/PCM/VCM Pinout Voltage The OE manufacture does not provide an ECM/PCM/VCM connector voltage pinout chart for this vehicle, only a function description. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment Engine Control Module: Service Precautions Aftermarket (Add-on) Electrical and Vacuum Equipment Aftermarket (Add-On) Electrical and Vacuum Equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicle's electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Notice: Do not add on any Add-On vacuum operated equipment to this vehicle. Notice: Connect the Add-On electrical operated equipment to the vehicle's electrical system at the battery (power and ground). Add-On electrical equipment, even when installed to these strict guidelines, may still cause the Powertrain system to malfunction. This may also include equipment not connected to the vehicle's electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any Powertrain problem is to eliminate all Aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 4709 Engine Control Module: Service Precautions Electrostatic Discharge Damage CAUTION: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board. Electronic components used in the control systems are often designed in order to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage; therefore, it is important to use care when handling and testing electronic components. The control module is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the control module circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the control module circuits unless instructed. Only test these circuits with a digital voltmeter J 39200, while the control module connectors remain connected to the control module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Aftermarket (Add-on) Electrical and Vacuum Equipment > Page 4710 Engine Control Module: Service Precautions Use of Circuit Testing Tools Do not use a test lamp in order to diagnose the Powertrain electrical systems unless specifically instructed by the diagnostic procedures. Use the Connector Test Adapter kit, J 35616 whenever diagnostic procedures call for probing any connectors. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) Engine Control Module: Description and Operation PCM Outputs (Qdsm & Odm) DESCRIPTION The Powertrain Control Module (PCM) controls most components with electronic switches which complete a ground circuit when turned "ON." These switches are arranged in groups of 4 and 7, called either a surface mounted Quad Driver Module (QDSM), which can independently control up to 4 outputs (PCM) terminals or Output driver Modules (ODMs) which can independently control up to 7 outputs. Not all outputs are always used. OPERATION Drivers are fault protected. If a relay or solenoid is shorted, having very low or zero resistance, or if the control side of the circuit is shorted to voltage, it would allow too much current flow into the PCM. The Driver senses this and the output is turned "OFF" or internal resistance increases to limit current flow and protect the PCM and the driver. The result is high output terminal voltage when it should be low. If the circuit from B+ to the component or if the component is open, or the control side of the circuit is shorted to ground, terminal voltage will be low. Either of these conditions is considered to be a driver fault. When and output is "ON," the terminal is grounded and its voltage will normally be low. When an output is "OFF," its terminal voltage normally will be high. QDSMs and ODMs also have a fault line to indicate the presence of a current fault to the PCM's central processor. A scan tool displays the status of the ODM fault lines as "0" = OK, "1" = Fault. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > PCM Outputs (Qdsm & Odm) > Page 4713 Engine Control Module: Description and Operation Powertrain Control Module (PCM) PURPOSE The Control Module refers to the Powertrain Control Module (PCM) and the Vehicle Control Module (VCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations: ^ Fuel control ^ Ignition Control (IC) ^ Knock Sensor (KS) system ^ Automatic transmission shift functions ^ Cruise Control Enable ^ Generator ^ Evaporative Emission (EVAP) Purge ^ A/C Clutch Control ^ Cooling Fan Control OPERATION The Control Module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The Control Module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following: ^ Quad Driver Module ^ Output Driver Modules The surface mounted Quad Driver Module can independently control up to 4 outputs (Control Module) terminals. The Output Driver Modules can independently control up to 7 outputs. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics A faulty PCM will be determined in the diagnostic tables. Before replacing the PCM, a re-programming procedure should not be attempted unless instructed. If the re-programming is unsuccessful a DTC P0602 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure Engine Control Module: Service and Repair Password Learn Procedure PASSWORD LEARN PROCEDURE In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the IPC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows: 1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes. 2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4718 Engine Control Module: Service and Repair PCM/EEPROM Replacement/Programming Note: Clear DTCs from the PCM any time either the PCM is reprogramed or the EGR valve is replaced, or anytime the ignition switch is turned on with the EGR valve electrical connector disconnected. This is due to the auto zeroing funtion of the PCM on the EGR pintle. Notice: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service of the PCM should normally consist of either replacement of the PCM, EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to see if it is the correct part. DTC P0601 indicates the EEPROM programming has malfunctioned. When DTC P0601 is obtained, re-program the EEPROM. The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. Removal Procedure Important: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to PCM (for example, battery cable, PCM Pigtail, PCM fuse, jumper cables, etc.). The ignition should be OFF for at least 10 seconds before disconnecting power to the PCM so the IAC valve has time to move to the engine OFF position. 1. Disconnect the negative battery cable. 2. Remove the RH engine splash shield. 3. Disconnect the horn electrical connector. 4. Remove the horn attaching bolt and horn. 5. Remove the PCM retainer attaching bolts (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4719 6. Slide the PCM and retainer(1) from PCM bracket (2). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 7. Disconnect the PCM electrical connectors (1). 8. Remove the retainer (1) from the PCM (2). Installation Procedure Remove the new PCM from its packaging and check the service number to make sure it is the same number or updated number as the faulty PCM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4720 Important: Refer to the latest Techline Information on Re-Programming or Flashing procedures. 1. Slide the PCM (2) into the PCM retainer (1). Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board. Do not remove the integrated circuit boards from the carrier. 2. Connect the PCM electrical connectors (1). 3. Slide the PCM and retainer (1) into the PCM bracket (2) slots. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Password Learn Procedure > Page 4721 4. Install the PCM retainer attaching bolts (1). Tighten the PCM retainer attaching bolts to 8-12 Nm (6-9 lb. ft.). 5. Connect the horn electrical connector and horn. 6. Install the horn attaching bolt. 7. Install the RH engine splash shield. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4761 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4762 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4796 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4797 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Left Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 4802 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4803 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperatures produce a high resistance (100,000 ohms at -40°C/-40°F), while high temperatures cause low resistance (70 ohms at 130°C/266°F). The Powertrain Control Module (PCM) uses this signal to determine the engine coolant temperature. OPERATION The PCM supplies a 5 volt signal to the ECT sensor through a resistor in the PCM and monitors the terminal voltage. Since this forms a series circuit to ground through the ECT sensor, high sensor resistance (low temperature) will result in high PCM terminal voltage. When the ECT sensor's resistance is low (high temperature), the terminal voltage will be drawn lower. This terminal voltage indicates engine coolant temperature to the PCM. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. Remember, these DTCs indicate a malfunction in the engine coolant temperature circuit, so proper use of the DTC table will lead to either repairing a wiring problem or replacing the sensor, to properly repair a problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4804 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection A scan tool displays the engine temperature in degrees Celsius. After the engine is started, the temperature should rise steadily to about 90°C (194°F) then stabilize when the thermostat opens. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A hard fault in the ECT sensor circuit should set either a DTC P0117 or P0118. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4805 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal Procedure Notice: Care must be taken when handling an Engine Coolant Temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system. 1. Turn the ignition switch OFF. 2. Relieve the coolant system pressure. 3. Disconnect the ECT sensor electrical connector. 4. Carefully back out the ECT sensor. Installation Procedure 1. Coat only the threads with sealer. 2. Install the ECT sensor in the engine, fully driven, seated and not stripped. 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4809 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4843 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4844 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Level Sensor: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4849 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4850 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4851 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4852 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4853 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 4854 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4855 Fuel Level Sensor: Description and Operation Purpose The Fuel Level Sensor is an important input to the Control Module for the enhanced evaporative system diagnostic. The fuel level information is needed for the Control Module to know the volume of the fuel tank. The fuel level affects the rate of charge in the air pressure in the EVAP system. Several of the Enhanced Evaporative System diagnostic sub-tests are dependent upon the correct fuel level information. Operation The fuel level sensor is attached to the modular fuel sender assembly. The resistance of the fuel sensor changes with fuel level by means of a rheostat. Its range is from 90 ohms with a full tank to 0 ohms with an empty tank. This resistance value is sent to the Instrument Panel Cluster (IPC) and displayed on the fuel gage. It is also sent to the PCM over UART serial data, and used for evaporative emissions system diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4856 Fuel Level Sensor: Testing and Inspection The PCM uses the fuel level input to determine the expected amount of vapor pressure or vacuum to expect within the fuel tank. The scan tool can displays fuel level in percent for diagnostic purposes. A DTC P0460 will be set if the PCM does not see a change in the fuel level after a certain time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Technical Service Bulletins > Page 4857 Fuel Level Sensor: Service and Repair Removal Procedure 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Drain fuel tank. Refer to Draining Fuel Tank. 3. Remove the fuel tank. Refer to Fuel Tank. 4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly. 5. Remove the bumper from modular fuel sender assembly. 6. Remove the fuel level sensor (1) from modular fuel sender. Installation Procedure 1. Fuel level sensor to modular fuel sender. 2. Install the bumper to modular fuel sender assembly. 3. Install the fuel sender assembly. Refer to Fuel Sender Assembly. 4. Install the fuel tank. Refer to Fuel Tank. 5. Refill tank. 6. Inspect for fuel leaks through the following steps: 6.1. Turn the ignition to the ON position for two seconds 6.2. Turn the ignition to the OFF position for ten seconds. 6.3. Turn the ignition to the ON position 6.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Description The Fuel Tank Pressure sensor is a 3 wire strain gauge sensor much like that of the common MAP sensor. However, this sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank sending unit. A three wire electrical harness connects it to the Control Module. The Control Module supplies a 5 volt reference voltage and ground to the sensor. The sensor sends a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor will measures 1.3 to 1.7 volts. Operation When the air pressure in the tank is 4.5 inches H2O (1.25 kPa), the sensor output voltage should measure 0.5 plus/minus 0.2 volts. When there is neither a vacuum or a pressure in the tank, the sensor voltage should be at 1.5 volts at 14 inches H2O (-3.75 kPa) the sensor output voltage should be 4.5 volts plus/minus 0.2 volts. When energized, the evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP canister to the engine. The normally closed valve is pulse width modulated by the Control Module in order to precisely control the vapor flow. The valve opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in the fuel tank and then closed in order to seal the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4861 Fuel Tank Pressure Sensor: Testing and Inspection The scan tool displays fuel tank pressure in volts and inches of water per second. The fuel tank pressure sensor is similar to the Manifold Absolute Pressure (MAP) sensor. It is used to measure the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The PCM supplies a 5 volt reference and a ground to the sensor and the sensor sends a voltage signal between 0.1 and 4.9 volts back to the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, as when the fuel cap is removed, the output voltage of the sensor will be from 1.3 to 1.7 volts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4862 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Perform Fuel Pressure Relief Procedure. 3. Drain fuel tank. 4. Remove the fuel tank. Refer to Fuel Tank. 5. Remove the electrical connector from the fuel tank vapor pressure sensor. 6. Remove the fuel tank vapor pressure sensor (1) from modular fuel sender. INSTALLATION PROCEDURE 1. Install the new fuel tank vapor pressure sensor (1) to modular fuel sender. 2. Install the electrical connector to fuel tank vapor pressure sensor. 3. Install the fuel tank. 4. Refill tank. 5. Install the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4868 LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 Intake Air Temperature Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 Wiring Diagram Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4903 Intake Air Temperature Sensor: Description and Operation OPERATION The Intake Air Temperature (IAT) sensor is a thermistor (a resistor which changes value based on the temperature of air entering the engine), similar to the Engine Coolant Temperature (ECT) sensor. Low temperature produces a high resistance (100,000 ohms at -40°C / -40°F) while high temperature causes low resistance (70 ohms at 130°C / 266°F). The Powertrain Control Module (PCM) supplies a 5 volt signal to the sensor through a resistor in the PCM and measures the terminal voltage. The voltage will be high when the intake air is cold, and low when the intake air is is hot. By measuring the voltage, the PCM knows the intake air temperature. This input is used in starting and running fuel control calculations. A failure in the IAT sensor circuit should set either a Diagnostic Trouble Code (DTC) P0112 or P0113. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4904 Intake Air Temperature Sensor: Testing and Inspection A scan tool displays the temperature of the air entering the engine, which should be close to ambient air temperature when engine is cold, and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the ECT and IAT temperatures should be close to each other. A fault in the IAT sensor circuit should set either a DTC P0112 or DTC P0113. The DTC tables also contain a table to check for sensor resistance values relative to temperature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4905 Intake Air Temperature Sensor: Service and Repair Removal Procedure The Intake Air Temperature (IAT) sensor is installed in the air induction flex tube. Care must be taken when handling a IAT sensor to avoid damage. 1. Turn the ignition switch OFF. 2. Disconnect the IAT sensor electrical connector. 3. Carefully remove the IAT sensor from air cleaner outlet duct. Installation Procedure 1. Install the IAT sensor into air cleaner outlet duct. 2. Connect the IAT sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls - Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Technical Service Bulletins > Page 4910 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 4913 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 4914 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4948 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4949 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor Attaching Screw ............................................................................................................. .................................................... 6.5 Nm (5.7 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4953 Manifold Pressure/Vacuum Sensor: Locations Front Right Of Engine Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4954 Manifold Pressure/Vacuum Sensor: Description and Operation MAP Sensor DESCRIPTION The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, and converts this measurement into a voltage output. OPERATION The PCM sends a 5 volt reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of the sensor also changes. By monitoring the sensor output voltage, the PCM can determine the manifold pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure, higher vacuum (low voltage) requires less fuel. A closed throttle on when the engine is decelerating would produce a relatively low MAP output, while a wide open throttle would produce a high output. Manifold absolute pressure is the opposite of what you would measure on a vacuum gage. When manifold pressure is high, vacuum is low. The MAP sensor is also used to measure barometric pressure under certain conditions, which allows the PCM to automatically adjust for different altitudes. A high or low voltage fault in the MAP sensor circuit should set a DTC P0107 or DTC P0108. If the MAP sensor sends an intermittent zero voltage signal to the PCM, a DTC P0106 will set. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4955 Manifold Pressure/Vacuum Sensor: Testing and Inspection A scan tool displays manifold pressure in kPa and MAP sensor signal voltage. Low pressure (high vacuum) displays a low voltage while a high pressure (low vacuum) displays a high voltage. A failure in the MAP sensor circuit should set a DTC P0107 or P0108 and using the applicable table will lead to the cause of the problem. A DTC P0108 may be set if misfire or a rough or unstable idle exists. A DTC P0105 will set for a MAP sensor that intermittently sends a zero voltage signal to the PCM. MAP Sensor Output Check 2.4L can also be used to check the MAP sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 4956 Manifold Pressure/Vacuum Sensor: Service and Repair Removal Procedure 1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor attaching screws (1). 4. Remove the MAP sensor vacuum hose (2). Installation Procedure 1. Connect the vacuum hose (2). 2. Install the MAP sensor attaching screw (1). Tighten the attaching screw to 6.5 Nm (5.7 lb. in.). 3. Connect the MAP sensor electrical connector. 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems Oxygen Sensor: Technical Service Bulletins Oxygen Sensor - Locations in Various Exhaust Systems File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 4964 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 4965 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensor - Locations in Various Exhaust Systems > Page 4966 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to misidentification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 4967 Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ....................................................... 41 Nm (30 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Technical Service Bulletin Update File In Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-40 Date: March, 1997 INFORMATION Subject: Pictorial of Oxygen Sensor Designations in Various Exhaust Systems Configurations Models: 1996-97 Passenger Cars, Geos and Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4970 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4971 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4972 Pictorials of the designation of oxygen sensors in General Motors vehicles. There has been some confusion relative to OBD II oxygen sensor designation. The intent of this bulletin is to eliminate misdiagnosis of those oxygen sensors due to mis-identification. When using Section 6E of the Service Manual, this chart can help locate the appropriate bank and sensor for the diagnostic. For "V" engines; BANK 1 is always on the side of the engine with the number 1 cylinder (odd cylinders), and BANK 2 is always on the side of the engine where the number 2 cylinder (even cylinders) is located. Just a reminder, the OBD II P-codes, technician observations and customer comments are all to be recorded on the repair order in accordance with article 1.6.2G of the GM Service Policies and Procedures Manual. Use the approved labor operation for the sensors replaced. J 6372 is used for engine out sensors. Labor Operation J 6380 is for the pre-sensor (the sensor just in front of the catalytic converter) and the post sensor (the sensor behind the catalytic converter). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4973 Component Location Views Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4974 LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4975 LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4976 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4977 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 Oxygen Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Post - Converter Heated Oxygen Sensor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) Oxygen Sensor: Description and Operation Oxygen Sensor (O2S 1) Purpose The Oxygen Sensor (02S 1) is mounted in the exhaust system where it can monitor the oxygen content of the exhaust gas stream. The oxygen content in the exhaust reacts with the sensor to produce a voltage output. This voltage ranges from approximately .1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). This voltage can be measured with a scan tool. Operation By monitoring the voltage output of the 02S 1, the PCM will know what fuel mixture command to give to the injectors. - Lean mixture-low 02S 1 voltage = rich command - Rich mixture - high 02S 1 voltage = lean command The 02S 1, if open, should set a DTC P0134. A constant low voltage in the sensor circuit should set a DTC P0131. A constant high voltage in the circuit should set a DTC P0132. DTCs P0131 and P0132 could also be set as a result of fuel system problems. See DTC tables for conditions that can cause a lean or rich system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 5014 Oxygen Sensor: Description and Operation Heated Oxygen Sensor 2 (HO2S 2) Catalyst Monitor The Rear Heated Oxygen Sensor (HO2S 2)is used to monitor the oxygen storage capability of the catalytic converter. Similar to the 02S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to .9 volt (low oxygen - rich mixture). Unlike the 02S 1, with a good catalytic converter, the HO2S 2 is normal when its activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 5015 Oxygen Sensor: Description and Operation Catalyst Monitor Diagnostic Operation The OBD II catalyst monitor diagnostic measures oxygen storage capacity. In order to do this, the heated sensors are installed before and after the Three-Way Catalyst (TWC). Voltage variations between the sensors allow the control module to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalyst's capacity to store and release oxygen generally degrades. The OBD II catalyst monitor diagnostic is based on an correlation between conversion efficiency and oxygen storage capacity. A good catalyst (e.g. 95% hydrocarbon conversion efficiency) shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor (HO2S). A degraded catalyst (65% hydrocarbon conversion) shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S 2 is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst; low oxygen storage capacity indicates a failing catalyst. The TWC, HO2S 2, and HO2S 3 must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the Post-Catalyst HO2S 3 Outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S Contamination ^ Alternate fuels Exhaust system leaks may cause the following results: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevents the TWC diagnostic from functioning properly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Oxygen Sensor (O2S 1) > Page 5016 Oxygen Sensor: Description and Operation HO2S Heater The oxygen sensor heaters are required by catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) Oxygen Sensor: Testing and Inspection Oxygen Sensor (O2S 1) A scan tool has several parameters that indicate the state of the exhaust gases: O2S 1 voltage, Short Term (S. T.) fuel trim, and Long Term (L. T.) fuel trim. A problem in the O2S 1 circuit should set a DTC P0134 (open circuit), DTC P0131 (lean exhaust indication), or DTC P0132 (rich exhaust indication). A faulty or lazy sensor will set a DTC P0133 (slow response) or a DTC P1133 (insufficient switching). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Oxygen Sensor (O2S 1) > Page 5019 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor (H02S 2) The Rear Heated Oxygen Sensor (HO2S 2) is used to monitor the oxygen storage capability of the catalytic converter. Similar to the O2S 1, the HO2S 2 reacts with the oxygen content in the exhaust stream to produce a voltage signal, only after the catalytic converter. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). Unlike the O2S 1, with a good catalytic converter, the HO2S 2 is normal when the activity appears lazy or inactive. The PCM compares readings from both the front O2S 1 and the HO2S 2 to determine the catalyst efficiency and will illuminate the MIL if this efficiency falls below a calibrated level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement Oxygen Sensor: Service and Repair Oxygen (O2S) Sensor Replacement O2S Service Removal Procedure Notice: The 02S 1 uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the oxygen sensor. Important: Take care when handling the Oxygen Sensor (02S 1). The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the 02S 1. Important: The 02S 1 may be difficult to remove when the engine temperature is below 48°C (120°F). Notice: Excessive force may damage the threads in the exhaust pipe. 1. Turn the ignition switch OFF. 2. Disconnect the Oxygen Sensor 1 electrical connector (1). 3. Carefully remove the oxygen sensor (2). Installation Procedure Important: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the oxygen sensor (2) with anti-seize compound, if necessary. 2. Install the Oxygen Sensor (2). Tighten the 02S 1 41 Nm (30 lb. ft.). 3. Connect the Oxygen Sensor 1 electrical connector (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen (O2S) Sensor Replacement > Page 5022 Oxygen Sensor: Service and Repair Catalyst Monitor (HO2S) Oxygen Sensors Removal Procedure Notice: The HO2S 2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the rear heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the rear heated oxygen sensor. Important: Take care when handling the Rear Heated Oxygen Sensor 2 (HO2S 2). The in-line electrical connector and louvered end like the O2S 1 must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn the ignition switch OFF. 2. Disconnect the HO2S 2 electrical connector. Notice: Excessive force may damage the threads in the exhaust pipe. 3. Carefully remove the rear heated oxygen sensor 2. Installation Procedure Important: A special anti-seize compound is used on the HO2S 2 sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If the sensor is removed from the exhaust, and if for any reason it is to be reinstalled, the threads must have an anti-seize compound applied before reinstallation. 1. Coat the threads of the HO2S 2 with anti-seize compound, if necessary. 2. Install the HO2S 2. Tighten the HO2S 2 to 41 Nm (30 lb. ft.). 3. Connect the HO2S 2 electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 5026 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5060 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5061 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5062 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5071 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5072 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON > Page 5078 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON > Page 5079 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 5091 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5092 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5093 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5094 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 5097 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 5098 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 5099 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits Vehicle Speed Sensor: Technical Service Bulletins Instruments - New Diagnostic Tables For VSS Circuits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-81-32 Date: May, 1997 SERVICE MANUAL UPDATE Subject: Section 8A - Electrical Diagnosis - New Diagnostic Tables for Vehicle Speed Sensor Signal Circuit Models: 1996-97 Buick Skylark 1996 Chevrolet Beretta, Corsica 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1997 Oldsmobile Cutlass 1996-97 Pontiac Grand Am, Sunfire This bulletin is being issued to add new diagnostic tables to Section 8A of the Service Manual. The tables included describe the diagnostic procedures for the diagnosis of the Vehicle Speed Sensor signal circuit from the Powertrain Control Module (PCM) to auxiliary devices. Please insert the included diagnostic tables into the Electrical Diagnosis Instrument Cluster section (Cell 80 J/L/N cars; Cell 81 L/N cars) of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5104 8A - 1 - 1 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5105 8A - 1 - 2 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5106 8A - 1 - 3 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5107 8A - 1 - 4 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5108 8A - 1 - 5 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5109 8A - 1 - 6 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5110 8A - 1 - 7 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5111 8A - 1 - 8 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5112 8A - 1 - 9 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5113 8A - 1 - 10 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5114 8A - 1 - 11 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5115 8A - 1 - 12 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5116 8A - 1 - 13 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5117 8A - 1 - 14 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5118 8A - 1 - 15 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5119 8A - 1 - 16 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5120 8A - 1 - 17 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5121 8A - 1 - 18 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5122 8A - 1 - 19 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5123 8A - 1 - 20 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5124 8A - 1 - 21 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5125 8A - 1 - 22 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5126 8A - 1 - 23 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5127 8A - 1 - 24 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5128 8A - 1 - 25 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5129 8A - 1 - 26 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5130 8A - 1 - 27 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5131 8A - 1 - 28 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5132 Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 5166 Vehicle Speed Sensor: Description and Operation Description The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Trans. for more information. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 5167 Vehicle Speed Sensor: Testing and Inspection A scan tool km/h MPH display should closely match the speedometer reading with drive wheels turning. A malfunction in the Vehicle Speed Sensor ( VSS) circuit will set a DTC P0502. Refer to Automatic Trans. if a problem exists with the VSS. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 Vehicle Speed Sensor: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Vehicle speed sensor (VSS) lead from transaxle. 3. Speed sensor housing bolts and housing. 4. Speed sensor housing O-ring. INSTALL OR CONNECT 1. Speed sensor housing O-ring. - Lubricate with DEXRON III. 2. Speed sensor housing and bolts. 3. VSS lead to transaxle. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 5170 Vehicle Speed Sensor: Service and Repair Isuzu 76mm REMOVE OR DISCONNECT 1. Vehicle speed sensor (VSS) lead from the transaxle. 2. Bolt/screw and retainer. 3. VSS assembly. 4. O-ring. INSTALL OR CONNECT 1. VSS assembly with New O-ring. - Lubricate O-ring with Synchromesh Transaxle Fluid GM P/N 12345349. 2. VSS assembly. 3. Retainer and bolt/screw. Tighten Vehicle Speed Sensor to 9 N.m (80 lb. in.). 4. VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 5171 Vehicle Speed Sensor: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Raise and support-vehicle. 2. Electrical connector. 3. Bolt holding speed sensor. 4. Vehicle speed sensor from case extension. 5. O-ring from vehicle speed sensor. INSTALL OR CONNECT 1. O-ring onto vehicle speed sensor. 2. Vehicle speed sensor into case extension. 3. Bolt. Tighten Bolt to 11 N.m (97 lb. in.). 4. Electrical connector. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 5175 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5209 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5210 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 5211 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5220 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5221 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5227 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 5228 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 5240 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5241 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5242 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5243 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 5246 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 5247 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 5248 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits Vehicle Speed Sensor: Technical Service Bulletins Instruments - New Diagnostic Tables For VSS Circuits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-81-32 Date: May, 1997 SERVICE MANUAL UPDATE Subject: Section 8A - Electrical Diagnosis - New Diagnostic Tables for Vehicle Speed Sensor Signal Circuit Models: 1996-97 Buick Skylark 1996 Chevrolet Beretta, Corsica 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1997 Oldsmobile Cutlass 1996-97 Pontiac Grand Am, Sunfire This bulletin is being issued to add new diagnostic tables to Section 8A of the Service Manual. The tables included describe the diagnostic procedures for the diagnosis of the Vehicle Speed Sensor signal circuit from the Powertrain Control Module (PCM) to auxiliary devices. Please insert the included diagnostic tables into the Electrical Diagnosis Instrument Cluster section (Cell 80 J/L/N cars; Cell 81 L/N cars) of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5253 8A - 1 - 1 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5254 8A - 1 - 2 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5255 8A - 1 - 3 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5256 8A - 1 - 4 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5257 8A - 1 - 5 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5258 8A - 1 - 6 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5259 8A - 1 - 7 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5260 8A - 1 - 8 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5261 8A - 1 - 9 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5262 8A - 1 - 10 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5263 8A - 1 - 11 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5264 8A - 1 - 12 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5265 8A - 1 - 13 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5266 8A - 1 - 14 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5267 8A - 1 - 15 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5268 8A - 1 - 16 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5269 8A - 1 - 17 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5270 8A - 1 - 18 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5271 8A - 1 - 19 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5272 8A - 1 - 20 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5273 8A - 1 - 21 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5274 8A - 1 - 22 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5275 8A - 1 - 23 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5276 8A - 1 - 24 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5277 8A - 1 - 25 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5278 8A - 1 - 26 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5279 8A - 1 - 27 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 5280 8A - 1 - 28 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5281 Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Vehicle Speed Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 5315 Vehicle Speed Sensor: Description and Operation Description The Vehicle Speed Sensor (VSS) is a permanent magnet generator in the transaxle which sends an AC voltage signal to the PCM, which the PCM converts to Kilometers Per Hour (km/h) and Miles Per Hour (MPH). There are several different types of vehicle speed sensors. Refer to Automatic Trans. for more information. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 5316 Vehicle Speed Sensor: Testing and Inspection A scan tool km/h MPH display should closely match the speedometer reading with drive wheels turning. A malfunction in the Vehicle Speed Sensor ( VSS) circuit will set a DTC P0502. Refer to Automatic Trans. if a problem exists with the VSS. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 Vehicle Speed Sensor: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Vehicle speed sensor (VSS) lead from transaxle. 3. Speed sensor housing bolts and housing. 4. Speed sensor housing O-ring. INSTALL OR CONNECT 1. Speed sensor housing O-ring. - Lubricate with DEXRON III. 2. Speed sensor housing and bolts. 3. VSS lead to transaxle. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 5319 Vehicle Speed Sensor: Service and Repair Isuzu 76mm REMOVE OR DISCONNECT 1. Vehicle speed sensor (VSS) lead from the transaxle. 2. Bolt/screw and retainer. 3. VSS assembly. 4. O-ring. INSTALL OR CONNECT 1. VSS assembly with New O-ring. - Lubricate O-ring with Synchromesh Transaxle Fluid GM P/N 12345349. 2. VSS assembly. 3. Retainer and bolt/screw. Tighten Vehicle Speed Sensor to 9 N.m (80 lb. in.). 4. VSS lead to the transaxle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > 3T40 > Page 5320 Vehicle Speed Sensor: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Raise and support-vehicle. 2. Electrical connector. 3. Bolt holding speed sensor. 4. Vehicle speed sensor from case extension. 5. O-ring from vehicle speed sensor. INSTALL OR CONNECT 1. O-ring onto vehicle speed sensor. 2. Vehicle speed sensor into case extension. 3. Bolt. Tighten Bolt to 11 N.m (97 lb. in.). 4. Electrical connector. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation DESCRIPTION The operation of the charging system is monitored by the PCM. The PCM monitors the charging system loads and adjusts the idle speed accordingly. The PCM also sends information to the Instrument Panel Cluster (IPC) when the charging system is inoperative and tells the IPC to illuminate the volts telltale lamp. OPERATION The generator provides voltage to operate the vehicles electrical system and to charge the vehicles battery. A magnetic field is created when current flows through the rotor. This field rotates as the rotor is driven by the engine, creating an IAC voltage in the stator windings. The AC voltage is converted to DC voltage by the rectifier bridge and is supplied to the electrical system at the battery terminal. The PCM supplies 5 Volts through the L circuit to the generator. If the generator becomes inoperative, the PCM can detect the fault through the L circuit and tell the IPC to illuminate the volts telltale lamp. The PCM monitors the duty cycle of the generator through the F circuit. As the generator load increases, the PCM will adjust the idle speed accordingly. If the IPC does not see any activity from the PCM on the F circuit, the IPC will illuminate the volts telltale lamp. COMPONENTS The generator assembly is mounted to the front of the engine on the passenger side of the vehicle. The KS-type generator uses an internal regulator which features built-in fault detection. The Model KS-i 30 generator used on this vehicle, is not to be disassembled for service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Flange Attaching Bolt .......................................................................................................................... ..................................................... 30 Nm (22 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 5328 Component Location Views Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 5329 Catalytic Converter: Description and Operation PURPOSE The control module must monitor the Three-Way catalyst system (TWC) for efficiency. In order to accomplish this, the control module monitors the pre-catalyst and post-catalyst oxygen sensors. When the TWC is operating properly, the post-catalyst (2) oxygen sensor will have significantly less activity than the pre-catalyst (1) oxygen sensor. The TWC stores oxygen as needed during its normal reduction and oxidation process. The TWC releases oxygen as needed during its normal reduction and oxidation process. The control module calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst oxygen sensor's voltage levels. OPERATION Whenever the voltage levels of the post-catalyst (2) oxygen sensor nears the voltage levels that of the pre-catalyst (1) oxygen sensor, the catalysts efficiency is degraded. Stepped or staged testing levels allow the control module to statistically filter test information. This prevents falsely passing or falsely failing the oxygen storage capacity test. The calculations performed by the on-board diagnostic system are very complex. For this reason, do not use post catalyst oxygen sensor activity in order to determine the oxygen storage capacity unless directed by the electronic service information Three stages are used in order to monitor catalyst efficiency. Failure of the first stage indicates that the catalyst requires further testing in order to determine catalyst efficiency. Failure of the second stage indicates that the catalyst may be degraded. The third stage then looks at the inputs from the pre and post O2 sensors more closely before determining if the catalyst is indeed degraded. This further statistical processing is done to increase the accuracy of oxygen storage capacity type monitoring. Failing the first (stage 0) or second (stage 1) test Does Not indicate a failed catalyst. The catalyst may be marginal or the fuel sulfur content could be very high. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an Aftermarket catalyst does not contain the same amount of cerium as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. The EVAP system uses a switch located in the purge line between the canister and the purge valve in order to detect when the purge is occurring. This switch senses the flow from the engine through the purge valve. When no purge is present, the switch is closed, applying a 12 volt signal to the control module as a NO PURGE signal. When canister purging occurs, the switch opens, interrupting off the 12 volt signal to the control module. A scan tool display will indicate that purge is occurring. Clogging of the canister fresh air vent could allow the purge hose between the switch and canister to trap vacuum with the purge valve closed. This would result in a diagnostic indication of a purge valve stuck open or a vacuum switch failure. Similarly, leaks or blockages in the purge hoses may result in misdiagnosis of the purge valve or vacuum switch. When servicing a purge valve diagnostic trouble code, check the canister fresh air vent, vacuum switch and the integrity of all purge hoses prior to servicing the valve. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 5330 Catalytic Converter: Service and Repair CAUTION: When a flex decoupler joint is moved from the normal mounting position it is possible to over-flex and damage the joint. Always support the flex decoupler joint and pipe assembly to avoid over-flexing. The flex decoupler joint is designed to flex a maximum of six degrees which is equivalent to the pipes connected to the joint moving no more than 1 inch for every 1 foot length of pipe, (if the pipe connected to the joint is 3 feet long, the end of the pipe could be moved a maximum of 3 inches). REMOVAL PROCEDURE 1. Raise and support vehicle. 2. Support three way catalytic converter. 3. Intermediate pipe from three way catalytic converter. 4. Exhaust manifold pipe assembly from exhaust manifold. 5. Exhaust manifold and three way catalytic converter seals. 6. Clean flange surfaces. INSTALLATION PROCEDURE 1. Exhaust manifold and three way catalytic converter seals. 2. Exhaust manifold pipe assembly to exhaust manifold. 3. Intermediate pipe to three way catalytic converter. 4. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Locations Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications Purge Valve Mounting Bracket Nut ........................................................................................................................................................... 8 Nm (71 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Evaporative Emissions Canister Vent Solenoid RH Front Corner Behind Fascia Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Evaporative Emissions Canister Vent Solenoid > Page 5340 LH Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 5341 Canister Purge Solenoid: Description and Operation EVAP Canister Purge Valve When energized, the evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP canister to the engine. The normally closed valve is pulse width modulated by the Control Module in order to precisely control the vapor flow. The valve opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in the fuel tank and then closed in order to seal the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 5342 Canister Purge Solenoid: Testing and Inspection The Purge Valve Leak Test runs only if there was a cold start this ignition, and the Weak Vacuum Test-Stage 1 test did not fail. This test monitors the purge valve for leaks. During the test monitors the purge valves for leaks. During the test both the vent and the purge valves close. If a vacuum develops, the purge valve is leaking and a DTC P1441 is reported. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 5343 Canister Purge Solenoid: Service and Repair Evap Canister And Vent Valve Removal Procedure Notice: The EVAP canister may have released carbon particles which may have caused this parts failure. Check the EVAP canister for carbon before returning to the vehicle to service. 1. Disconnect the purge valve electrical connector. 2. Remove the hoses (3), (4) to the purge valve. 3. Remove the purge valve (1) from the mounting bracket. 4. Remove the purge valve mounting bracket attaching nut (when replacing bracket). 5. Remove the purge valve mounting bracket. Installation Procedure 1. Install the purge valve mounting bracket and attaching nut. Tighten the purge valve mounting bracket attaching nut to 8 Nm (71 lb. in.). 2. Slide the purge valve (1) onto mounting bracket. 3. Install the hoses (3), (4) to the purge valve (1). 4. Connect the purge valve electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Description and Operation Canister Vent Valve: Description and Operation Evaporative Canister Vent Valve Description The Evaporative Canister Vent Valve replaces the fresh air vent used on the past EVAP canisters. Operation The vent valve now not only allows the fresh outside air to the EVAP canister during the purge modes, but also allows the diagnostic to pull a vacuum on the fuel tank by closing the vent valve. This valve is normally open. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Description and Operation > Page 5348 Canister Vent Valve: Service and Repair Evap Canister And Vent Valve Removal Procedure 1. Remove the RH engine splash shield. 2. Disconnect the vent solenoid electrical connector. 3. Remove the vent solenoid hose clamp. 4. Disconnect the hose (3) to the vent solenoid (4). 5. Remove the vent solenoid (4) from mounting bracket. Installation Procedure 1. Slide the vent solenoid onto the mounting bracket. 2. Lubricate the hose ends with lubricant. 3. Connect the hose (3) to the vent solenoid (4). 4. Connect the vent solenoid hose clamp. 5. Connect the vent solenoid electrical connector. 6. Install the RH engine splash shield. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation EVAP Service Port DESCRIPTION The Evaporative System Service Port is located in the evaporative hose located between the purge solenoid and the canister. The service port is identified by a green colored cap. The port contains a schrader valve and fittings in order to allow the connection of the service tool kit Enhanced EVAP Pressure Purge Diagnostic Cart J 41413. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations EGR Control Solenoid: Locations Front Right Of Engine LH Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service EGR Valve: Technical Service Bulletins Engine Controls - Clear DTC's After PCM/VCM/EGR Service File In Section: 6E - Engine Fuel & Emission Bulletin No.: 61-65-59 Date: December, 1996 SERVICE MANUAL UPDATE Subject: Section 6E - Engine Controls - Clear DTCs after PCM or VCM Replacement/Programming or EGR Valve Replacement Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva, Cutlass 1997 Pontiac Grand Am, Sunfire 1995-97 Chevrolet and GMC S/T, M/L, C/K, G, P3 Models 1996-97 Oldsmobile Bravada with 2.2L, 2.4L, 4.3L, 5.0L, 5.7L, 7.4L Engine (VINs 4, T, J, M, R, W, X - RPOs LN2, LD9, L29, L30, L31, L35, LF6) PCM Equipped Vehicles This bulletin is being issued to revise the 1997 GMP/97-N-2, 1997 GMP/97-J-2 and 1997 GMT/97-ST-2 Service Manuals. Make the following revisions to the EGR replacement P0404, DTC P0405, DTC P1404 and PCM EEPROM reprogramming sections of the Service Manual due to possible setting of EGR DTCs after performing these procedures. Clear DTCs from the PCM anytime either the PCM is reprogrammed or the EGR valve is replaced, or anytime the ignition switch is turned on with the EGR valve electrical connector disconnected. This is due to the auto zeroing function of the PCM on the EGR pintle. VCM Equipped Trucks This bulletin updates the following Service Manuals: 1997 1997 1997 GMT/97-ST-2 GMT/97-CK-2 GMT/97-ML-2 1997 1997 1997 GMT/97-G6-2 GMT/97-P3-2 GMT/96-ST-2 1996 1996 1996 GMT/96-CK-2 GMT/96-ML-2 GMT/96-G6-2 1996 1995 1995 GMT/96-P3-2 GMT/95-ST-2 GMT/95-CK-2 1995 1995 1995 GMT/95-ML-2 GMT/95-G6-2 GMT/95-P3-2 Add the following revision to these Engine Controls sections: EGR Valve Replacement, VCM Replacement/Programming, EGR System Diagnosis, DTC P0401 and DTC P1406. Clear any DTCs from the VCM anytime after doing VCM Replacement/programming, turning the ignition ON while the EGR valve is disconnected, or replacing the EGR valve. Please make a note of these revisions in your Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5360 EGR Valve: Technical Service Bulletins EGR - Revised DTC P1404 (Closed Pintle Position) Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 61-65-58 Date: December, 1996 SERVICE MANUAL UPDATE Subject: Section 6E3 - Driveability and Emissions - Revised DTC P1404 EGR Valve Closed Pintle Position Table Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva, Cutlass 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P1404 EGR Valve Closed Pintle Position Table in the following Service Manuals: ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 ^ 1997 GMP/97-LN-2 ^ 1997 GMT/97-ST-2 A revised copy of the diagnostic table is included. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5361 6-238 Engine Controls - 2.2L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5362 6-239 Engine Controls - 2.2L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5363 6-240 Engine Controls - 2.2L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5364 6E-630 Engine Controls - 2.2L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5365 6E-631 Engine Controls - 2.2L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5366 6E-632 Engine Controls - 2.2L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5367 6-228 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5368 6-229 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5369 6-230 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5370 6-231 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5371 6-232 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5372 6-233 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5373 6-646 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5374 6-647 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine Controls - Clear DTC's After PCM/VCM/EGR Service > Page 5375 6-648 Engine Controls - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 5376 EGR Valve: Specifications EGR Valve Bolts .................................................................................................................................. ........................................... 22-30 Nm (16-22 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 5377 EGR Valve Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 5378 EGR Valve: Service and Repair EGR Valve Removal Procedure 1. Remove the Air Cleaner Outlet Resonator. Refer to Air Cleaner Outlet Resonator 2. Disconnect the electrical connector to the EGR valve. 3. Remove the EGR valve bolts (1). 4. Remove the EGR valve (2). Installation Procedure Important: Be sure all gasket material is removed from the EGR mounting surface. Even a small amount of material may cause a DTC P0401 to set. 1. Install the EGR valve (2) with the gasket (3). 2. Install the EGR valve bolts (1). Tighten the EGR valve bolts to 26 Nm (19 lb. ft.). 3. Connect the EGR valve electrical connector. 4. Install the Air Cleaner Outlet Resonator. Refer to Air Cleaner Outlet Resonator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation DESCRIPTION To prevent refueling with leaded fuel, the fuel filler neck is equipped with restrictor and deflector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Oil Separator > Component Information > Specifications Oil Separator: Specifications Oil/Air Separator Bolts ......................................................................................................................... ..................................................... 24 Nm (17 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Oil Separator > Component Information > Specifications > Page 5386 Oil Separator: Service and Repair Removal Procedure 1. Remove the Air cleaner outlet resonator. 2. Remove the intake manifold. 3. Disconnect the oil/air separator vent hoses (1). 4. Remove the oil/air separator mounting bolts (2). 5. Remove the oil/air separator assembly (3). Installation Procedure 1. Install the oil/air separator assembly (3). 2. Install the oil/air separator mounting bolts (2). Tighten the Oil/Air separator mounting bolts to 24 Nm (17 lb. ft.). Notice: When installing hoses, apply a small film of soap to the inside edges of the hose prior to installation. 3. Connect the oil/air separator vent hoses (1). 4. Install the intake manifold. 5. Connect the Air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure > Page 5392 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5393 Fuel Pressure: Service Precautions CAUTION: The following procedures and conditions MUST be followed or parts and system damage could result. 1. Do not operate the fuel pump without fuel in the lines. 2. Torque all screw couple fittings and fasteners to the specified torque. 3. If a fastener needs to be replaced, use the correct part number fastener or a fastener of equal size and strength (or stronger) for that application. 4. Always use a backup wrench when loosening or tighting a screw couple fitting. 5. On fuel injected models do not depress the accelerator pedal while trying to start the car. 6. Handle all fuel injection related parts with care as they may easily be damaged. 7. Always use new gaskets or O-rings when installing fuel lines or injectors. 8. Lightly lubricate O-rings and flare connections with gasoline. Do NOT use engine oil, gear lubricant or brake fluid. 9. Take care not to nick or scratch any nylon fuel lines. If damaged, they must be replaced. 10. Always cover nylon fuel lines with a wet towel before using a torch near them. Never expose the vehicle to temperatures higher than 115°C (239° F) for more than one hour, or more than 90°C (194°F) for any extended period. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5394 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5395 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5396 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5397 Diagnostic Chart Gauge Hookups CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn the in-tank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION Number(s) below refer to the step number(s) on the Diagnostic Table. 2. To relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition switch is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gage should be 284-325 kPa (41-47 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that can not maintain a constant fuel pressure has a leak in one or more of the following areas: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5398 ^ The fuel pump check valve. ^ The fuel pump flex pipe. ^ The valve or valve seat within the fuel pressure regulator. ^ The fuel injector(s). 4. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector width will increase. NOTE: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. This can cause false indications by the scan tool. 7. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the Engine OFF. 11. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 12. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a faulty fuel pressure regulator. 15. A lean condition may result from the fuel pressure being below 284 kPa (41 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold), hesitation, poor driveability, lack of power, surging, and misfiring. 16. Restricting the fuel return pipe causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gage outlet hose is pinched. 22. Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. 24. The fuel pressure regulator filter screen is designed to trap any contaminants introduced during engine assembly. If the fuel pressure regulator screen is dirty, it can be removed with a small pick and discarded without potential harm to the fuel pressure regulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: Customer Interest Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 5410 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Idle Speed: All Technical Service Bulletins Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 5416 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5417 Idle Speed: By Symptom Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5418 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5419 Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5420 For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5421 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Technical Service Bulletin # 77-61-09B Date: 971001 Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5422 Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 5423 Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 5424 Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications > Page 5428 Air/Fuel Mixture: Adjustments The Air / Fuel mixture is controlled by the Powertrain Control Module and is not adjustable. If Air / Fuel mixture is incorrect begin diagnosis at Powertrain Management / System Diagnosis / Flow of Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Pedal Assembly Nuts .......................................................................................................................... ....................................................... 30 Nm (25 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 5432 Accelerator Pedal: Service and Repair Removal Procedure 1. Remove left sound insulator. 2. Remove the release cable (1) retainer from lever assembly. 3. Remove the nuts to cowl. 4. Remove the pedal assembly (2). Installation Procedure 1. Install the pedal assembly (2) to cowl. 2. Install the nuts to cowl. Tighten the nuts to 30 Nm (25 lb. ft.). 3. Slip accelerator cable (1) through slot in rod and then install retainer in rod, being sure it is seated. 4. Install the left sound insulator. Important: Flexible components (hoses, wires, conduits, etc.) must not be routed within 50 mm (2.0 in) of moving parts of accelerator linkage outboard of support unless routing is positively controlled. 5. Check for correct opening and closing positions by operating accelerator pedal. Make sure that the throttle valve reaches wide-open throttle position. If it does not, inspect for damaged or bent brackets, levers, or other components; or, for poor carpet in under the accelerator pedal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Specifications Air Cleaner Fresh Air Duct/Hose: Specifications Resonator Upper Attaching Bolt .......................................................................................................... ....................................................... 7 Nm (61 lb. in.) Headlamp Assembly Retaining Screws ....................................................................................................................................................... 7 Nm (61 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct Air Cleaner Fresh Air Duct/Hose: Service and Repair Front Air Duct Removal Procedure 1. Remove the air cleaner outlet splash shield. 2. Remove the LH headlamp assembly retaining screws. 3. Remove the LH headlamp assembly. 4. Disconnect the LH headlamp electrical connector(s). 5. Remove the front air cleaner outlet duct upper push in retainer. 6. Remove the resonator front push in retainer. 7. Raise the vehicle. 8. Remove the LF tire and wheel. 9. Remove the LF wheel house panel. 10. Remove the front air cleaner outlet duct lower retaining screw. 11. Remove the front air cleaner outlet duct through headlamp assembly opening. 12. Remove the resonator rear push in retainer and upper attaching bolt. 13. Remove the resonator assembly through wheel house opening. Installation Procedure 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push in retainer and the upper attaching bolt. Tighten the Resonator upper attaching bolt to 7 Nm (61 lb. in.). 3. Install the front air cleaner outlet duct through the headlamp assembly opening. 4. Install the front air cleaner outlet duct lower retaining screw. 5. Install the LF wheel house panel. 6. Install the LF tire and wheel. 7. Lower the vehicle. 8. Install the resonator front push in retainer. 9. Install the front air cleaner outlet duct upper push in retainer. 10. Install the LH headlamp electrical connector(s). 11. Install the LH headlamp assembly retaining screws. Tighten the headlamp assembly retaining screws to 7 Nm (61 lb. in.). 12. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Front Air Duct > Page 5439 Air Cleaner Fresh Air Duct/Hose: Service and Repair Fresh Air Hose Removal Procedure 1. Remove the air cleaner outlet resonator mounting screws. 2. Disconnect the air cleaner outlet resonator clamp at throttle body. 3. Remove the air cleaner outlet duct from air cleaner outlet resonator and air cleaner assembly. 4. Disconnect the crankcase vent hose from the air cleaner outlet duct. 5. Remove the air cleaner outlet resonator. Installation Procedure Important: Be sure that the air cleaner outlet resonator seals to the throttle body. 1. Install the air cleaner outlet resonator to the throttle body. 2. Connect the crankcase vent hose to the air cleaner outlet duct. 3. Install the air cleaner outlet resonator mounting screws. Tighten: ^ Air cleaner outlet resonator mounting screws to 5-7 Nm 60-84 lb. in.). ^ Air cleaner outlet resonator clamp to 4-5 Nm 35-44 lb in). 4. Install the air cleaner outlet duct to the air cleaner outlet resonator and the air cleaner assembly. Tighten Air cleaner outlet duct clamps to 45 Nm (35-44 lb. in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5448 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5454 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5455 Air Filter Element: Specifications Air Cleaner Cover Screws ................................................................................................................... ........................................................ 3 Nm (26 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5456 Air Filter Element: Service and Repair Air Filter Removal Procedure 1. Remove the upper air cleaner screws. 2. Remove the air cleaner cover. 3. Remove the air cleaner filter from lower air cleaner housing. 4. Inspect the air cleaner filter for dust, dirt, and water. 5. Replace if required. Installation Procedure 1. Install the air cleaner filter into the lower air cleaner housing. 2. Install the air cleaner cover to air cleaner housing. 3. Install the air cleaner screws. Tighten the air cleaner cover screws to 3 Nm (26 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation DESCRIPTION To prevent refueling with leaded fuel, the fuel filler neck is equipped with restrictor and deflector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5499 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5500 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5501 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5502 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5503 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5504 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5505 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5506 Fuel: Specifications Gasoline All engines are designed to use unleaded fuel only. Unleaded fuel must be used for proper emission control system operation. It's use will also minimize spark plug fouling and extend engine oil life. Using leaded fuel can damage the emission control system and could result in loss of emission warranty coverage. The fuel should meet specification ASTM D4814 for the U.S. or CGSB 3.5 M93 for Canada. All engines are designed to use unleaded fuel with a minimum U(R+M)/2e (pump) octane number of 87, where; R=research octane number, and M=motor octane number. Ethanol You may use fuel containing ethanol (ethyl) or grain alcohol providing that there is no more than 10 percent ethanol alcohol by volume. Methanol Do not use fuels containing methanol. Methanol can corrode metal parts and also cause damage to plastic and rubber parts in the fuel system. Methyl Tertiary-Butyl Ether (MTBE) You may use fuel containing Methyl Tertiary-Butyl Ether (MTBE) providing there is no more than 15 percent MTBE by volume. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5507 Fuel: Testing and Inspection PROCEDURE Alcohol concentrations greater than 10% in fuel can be detrimental to fuel system components and may cause driveability problems such as hesitation, lack of power, stall, no start, etc. The problems may be due to fuel system corrosion and subsequent fuel filter plugging, deterioration of rubber components, and/or air/fuel mixture leaning. Various types and concentrations of alcohol are used in commercial fuel. Some alcohol is more detrimental to fuel system components than others. If an excessive amount of alcohol in the fuel is suspected as the cause of a driveability condition, the following procedure may be used to detect the presence of alcohol in the fuel. TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water (as indicated by a water layer at the bottom of the sample), this procedure should not be used, and the fuel system should be cleaned. 1. Using a 100 ml specified cylinder with 1 ml graduation marks, fill the cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper. 3. Shake the cylinder vigorously for 10 to 15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10 to 15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer (which would now contain both alcohol and water) will be greater than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat greater because this procedure does not extract all of the alcohol from the fuel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation Fuel Filler Neck And Cap PURPOSE The fuel tank filler neck is equipped with a screw type cap. The threaded part of the cap requires several turns counter-clockwise to remove. The long threaded area is designed to allow any remaining fuel tank pressure to escape during the cap removal operation. OPERATION A built-in rachet type torque limiting device prevents over-tightening. To install, turn the cap clockwise until a clicking noise is heard. This signals that the correct torque has been reached and the cap is fully seated. NOTICE: If a fuel filler cap requires replacement, only a cap with the same features should be used. Failure to use the correct cap can result in a serious malfunction of the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Procedure 1. Loosen the fuel filler cap in order to relieve the tank pressure (do not tighten at this time). 2. Raise the vehicle. 3. Disconnect the fuel pump electrical connector. 4. Lower the vehicle. 5. Start and run the engine until the fuel supply remaining in the fuel pipes is consumed. Engage the starter for 3.0 seconds in order to assure relief of any remaining pressure. 6. Raise the vehicle. 7. Connect the fuel pump electrical connector. 8. Lower the vehicle. 9. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Voltage Voltage ECT between 50-95 degrees F (10-35 degrees C) Injector Voltage Reading 4.7- 5.8 Volts Please refer to Fuel Injector Coil Test procedure at Computers and Contol Systems Testing. Resistance Ohms Resistance Ohms ECT between 50 - 95 degrees F (10 - 35 degrees C) Ohms 1.95-2.3 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 5521 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Pressure Drop Fuel Injector Pressure Drop If the pressure drop value for each injector is within 1.5 psi of the average drop value the fuel injectors are flowing properly. Pressure Drop 1.5 psi Fuel Injector Balance Test Example (Typical) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injectors Center Rear Of Engine Compartment (VIN T), (VIN 4 Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injectors > Page 5524 Fuel Injector: Locations Injectors Harness Front Right Of Engine Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Fuel Injector: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5558 Fuel Injector: Description and Operation Purpose The fuel injector assembly is a solenoid-operated device, controlled by the PCM, that meters pressurized fuel to a single engine cylinder. Operation The PCM energizes the fuel injector solenoid, which opens a ball valve, allowing fuel to flow past the ball valve, and through a recessed flow director plate at the injector outlet. The director plate has machined holes that control the fuel flow, generating a conical spray pattern of finely atomized fuel at the injector tip. Fuel from the tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. A fuel injector that is stuck partly open would cause loss of pressure after the engine is shut down, so long crank times would be noticed on some engines. Dieseling could also occur because some fuel could be delivered to the engine after the ignition is turned OFF. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 5559 Fuel Injector: Testing and Inspection Most GM manufacturers now use a voltage drop and/or a fuel pressure drop test to measure Fuel Injector Coil Integrity. These test sequences can be found in Computers and Control Systems, under A, C or System Diagnostic Charts. See: Computers and Control Systems/Testing and Inspection Within these tests you might find an "Ohm" reading of the Injector, but generally this measurement is No Longer Used to solely determine the Pass/Fail quality of the Injector coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Tools - Fuel Line Quick Connect Remover Deleted Fuel Line Coupler: Technical Service Bulletins Tools - Fuel Line Quick Connect Remover Deleted File In Section: 1 - HVAC Bulletin No.: 63-11-12 Date: October, 1996 SERVICE MANUAL UPDATE Subject: Section 1A - Deletion of Reference to Special Tool J 42202 Models: 1997 Buick Skylark 1997 Chevrolet Cavalier 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire This bulletin is being issued to delete all references to Special Tool J 42202, Quick Connect Remover, found in Section 1A of the Service Manual. The tool is not needed to separate the quick connect fitting and is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Page 5564 Fuel Line Coupler: Service Precautions WARNING: To Reduce the Risk of Fire and Personal Injury: Always cover nylon fuel pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher then 115° C (239° F) for more than one hour, or more than 90° C (194° F) for any extended period. Take care not to nick or scratch the nylon fuel pipes. If damaged, they must be replaced . Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Page 5565 Fuel Line Coupler: Description and Operation Quick-Connect Fittings QUICK-CONNECT FITTINGS Quick-connect type fittings provide a simplified means of installing and connecting fuel system components. There are two types of quick-connect fittings used at different locations in the fuel system. Each type consists of a unique female socket and a compatible male connector. O-Rings, located inside the female socket, provide the fuel seal. Integral locking tabs or fingers hold the fittings together. FUEL PIPE O-RINGS Fuel feed and return pipe threaded connections at the fuel rail and fuel filter are sealed with replaceable O-Ring seals. These O-Rings seals are made of special material, and should only be serviced with the correct service part. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Page 5566 Fuel Line Coupler: Service and Repair Removal Procedure Tools Required J37O88 Tool Set, Fuel Line Quick-Connect Separator Important: Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. 1. Slide the dust cover from the quick-connect fitting. 2. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each direction to loosen any dirt within the fitting. Caution: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct tool from J37O88 Tool Set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Page 5567 5. Pull the connection apart. Notice: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the pipe end in order to prevent damage to the O-ring sealing surface. 6. Using a clean shop towel, wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Installation Procedure Caution: To Reduce the Risk of Fire and Personal Injury: Before connecting the fitting, always apply a few drops of clean engine oil to the male pipe end. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push connectors together to cause the retaining tabs / fingers to snap into place. 3. Once installed, pull on both ends of each connection to make sure they are secure. 4. Reposition dust cover over the quick-connect fitting. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Pressure Regulator Screw ................................................................................................................... .................................................. 11.5 Nm (102 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 5571 Fuel Pressure Regulator: Service and Repair Removal Procedure Fuel Rail Assembly 1. Relieve the fuel system pressure 2. Remove the negative battery cable. 3. Remove the fuel rail assembly (1) from engine. 4. Remove the pressure regulator attaching screw (10). 5. Remove the pressure regulator assembly (11) from fuel rail. Twist back and forth while pulling apart. Installation Procedure Fuel Rail Assembly Important: It fuel pressure regulator is to be reinstalled, inspect filter screen (12) for contamination. If contaminated remove and discard filter screen. 1. Lubricate new rail to regulator inlet fitting O-ring seal (13) with clean engine oil and install in regulator. 2. Install the regulator assembly (11). Important: Whenever there is not enough thread-locking material on the threads of reusable hardware, apply Loctite® 262 to ensure proper locking. 3. Install the pressure regulator attaching screw (10). Tighten Tighten the regulator attaching screw to 11.5 Nm (102 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 5572 4. Install the fuel rail assembly (1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Key On Engine Off 41-47 psi Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure > Page 5578 Fuel Pressure: Specifications Volume Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5579 Fuel Pressure: Service Precautions CAUTION: The following procedures and conditions MUST be followed or parts and system damage could result. 1. Do not operate the fuel pump without fuel in the lines. 2. Torque all screw couple fittings and fasteners to the specified torque. 3. If a fastener needs to be replaced, use the correct part number fastener or a fastener of equal size and strength (or stronger) for that application. 4. Always use a backup wrench when loosening or tighting a screw couple fitting. 5. On fuel injected models do not depress the accelerator pedal while trying to start the car. 6. Handle all fuel injection related parts with care as they may easily be damaged. 7. Always use new gaskets or O-rings when installing fuel lines or injectors. 8. Lightly lubricate O-rings and flare connections with gasoline. Do NOT use engine oil, gear lubricant or brake fluid. 9. Take care not to nick or scratch any nylon fuel lines. If damaged, they must be replaced. 10. Always cover nylon fuel lines with a wet towel before using a torch near them. Never expose the vehicle to temperatures higher than 115°C (239° F) for more than one hour, or more than 90°C (194°F) for any extended period. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5580 Fuel Pressure: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5581 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5582 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5583 Diagnostic Chart Gauge Hookups CIRCUIT DESCRIPTION When the ignition switch is turned ON, the Powertrain Control Module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving reference pulses. If there are no reference pulses, the PCM will turn the in-tank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail assembly, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return pipe. TEST DESCRIPTION Number(s) below refer to the step number(s) on the Diagnostic Table. 2. To relieve the fuel pressure, go to Fuel Pressure Relief Procedure When the ignition switch is ON and the fuel pump is running, the fuel pressure indicated by the fuel pressure gage should be 284-325 kPa (41-47 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that can not maintain a constant fuel pressure has a leak in one or more of the following areas: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5584 ^ The fuel pump check valve. ^ The fuel pump flex pipe. ^ The valve or valve seat within the fuel pressure regulator. ^ The fuel injector(s). 4. Fuel pressure that drops-off during acceleration, cruise or hard cornering may cause a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector width will increase. NOTE: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. This can cause false indications by the scan tool. 7. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in Step 2 with the Engine OFF. 11. A rich condition may result from the fuel pressure being above 325 kPa (47 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 12. This test determines if the high fuel pressure is due to a restricted fuel return pipe or if the high fuel pressure is due to a faulty fuel pressure regulator. 15. A lean condition may result from the fuel pressure being below 284 kPa (41 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold), hesitation, poor driveability, lack of power, surging, and misfiring. 16. Restricting the fuel return pipe causes the fuel pressure to rise above the regulated fuel pressure. Using a scan tool to pressurize the system, the fuel pressure should rise above 325 kPa (47 psi) as the gage outlet hose is pinched. 22. Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. 24. The fuel pressure regulator filter screen is designed to trap any contaminants introduced during engine assembly. If the fuel pressure regulator screen is dirty, it can be removed with a small pick and discarded without potential harm to the fuel pressure regulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5620 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 5621 Fuel Pump Relay: Service and Repair Fuel Pump Relay Removal Procedure 1. Remove the relay center cover. 2. Remove the Fuel Pump Relay. Installation Procedure 1. Install the Fuel Pump Relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation DESCRIPTION A woven plastic strainer is located on the lower end of the fuel sender. OPERATION This filter prevents dirt from entering the fuel line and also stops water unless the filter becomes completely submerged in water. This filter is self cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Therefore, should this occur, the fuel tank should be removed and thoroughly cleaned and the tank filter replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 5625 Fuel Pump Pickup Filter: Service and Repair Removal Procedure 1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release 2. Drain fuel tank. Refer to Draining Fuel Tank. 3. Remove the fuel tank. Refer to Fuel Tank. 4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly. 5. Note strainer position for future reference. 6. Support the reservoir with one hand and grasp the strainer with the other hand. 7. Using a screwdriver to pry the strainer ferrule off the reservoir. 8. Discard the strainer. Installation Procedure 1. Install the new strainer (1) to reservoir. 2. Support the reservoir with one hand and grasp the strainer with the other hand twisting the strainer into position. 3. Install the fuel sender assembly. Refer to Fuel Sender Assembly. 4. Install the fuel tank. Refer to Fuel Tank. 5. Refill tank. 6. Inspect for fuel leaks: 6.1. Turn the ignition switch to the ON position for two seconds. 6.2. Turn the ignition switch OFF position for ten seconds. 6.3. Turn the ignition switch to the ON position. 6.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Return Pipe Bracket Screw ................................................................................................................. ...................................................... 6.0 Nm (53 lb. in.) Fuel Inlet Pipe Nut .......................................... ........................................................................................................................................... 30 Nm (22 lb. ft.) Fuel Rail Assembly Attaching Bolts .......................................................................................................................................................... 26 Nm (19 lb. ft.) Inlet and Return Pipe Connection Fittings ................................................................................................................................................. 27 Nm (20 lb. ft.) Fuel Pipe Clamp Bolt ........................................................................................................... ................................................................... 12 Nm (106 lb. in.) Air Cleaner Resonator to Throttle Body Clamp .................................................................................................................................. 4-5 Nm (35-44 lb. in.) Air Cleaner Resonator Attaching Bolts ..................................................................................................................................................... 10 Nm (89 lb. in.) Air Cleaner Outlet Duct to Air Cleaner Resonator ............................................................................................................................. 4-5 Nm (35-44 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5629 Fuel Rail: Service and Repair Resonator Fuel Rail Assembly REMOVAL PROCEDURE 1. Perform the Fuel Pressure Relief Procedure. 2. Remove the negative battery cable. 3. Loosen the air cleaner outlet duct clamp. 4. Remove the air cleaner outlet duct from air cleaner resonator. 5. Loosen the air cleaner resonator clamp at the throttle body. 6. Remove the bolts (1) attaching the resonator. 7. Remove the air cleaner resonator (2) from the throttle body (3). 8. Remove the crankcase vent hose to bottom of resonator, then remove the resonator. 9. Remove the fuel pipe clamp bolt. 10. Remove the vacuum hose at pressure regulator. 11. Remove the fuel rail attaching bolts. 12. Remove the fuel rail assembly (1) from cylinder head. 13. Remove the injector electrical connectors. Push in wire connector clip, while pulling connector away from fuel injector. 14. Remove the fuel inlet pipe at fuel rail. (Use a backup wrench on the fuel rail inlet fitting to prevent it from turning). 15. Loosen fuel return pipe retaining bracket attaching screw (7). (Rotate retaining bracket (8) to allow fuel pipe to be removed). 16. Remove the fuel return pipe from pressure regulator (11). 17. Remove the fuel rail assembly. 18. Remove the inlet and return pipe to fuel feed and return line connections. 19. Remove the inlet and return pipe assemblies. Discard O-rings (9). INSTALLATION PROCEDURE NOTE: - Apply a few drops of clean engine oil to the male end of the fuel pipes before installing. - Whenever there is not enough thread-locking material on the threads of the fuel outlet pipe bracket screw, apply Loctite 262 to insure proper Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 5630 locking. 1. Whenever the fuel rail is disconnected from fuel pipes, reconnect fuel pipes to rail at this time. 2. Install the return pipe into regulator (11). - (Align bracket to retain return pipe). Tighten: Tighten Return pipe bracket screw (7) to 6.0 Nm (53 lb. in.). Use a backup wrench on the fitting to prevent it from turning. Fuel inlet pipe nut to 30 Nm (22 lb. ft.). Important: Rotate fuel injector(3) as required to avoid stretching the wire harness. 3. Position fuel rail (1) over cylinder head and connect fuel injector electrical connectors. 4. Install the fuel rail assembly into cylinder head. 5. Install the fuel rail assembly attaching bolts. Tighten Bolts to 26 Nm (19 lb. ft.). 6. Install the vacuum hose to fuel pressure regulator (11). 7. If front (engine) fuel pipes are being replaced, install new fuel pipe O-rings (9), coated with clean engine oil. - Use a backup wrench to prevent female fitting from turning. 8. Install the inlet and return pipe connections. Tighten Fittings to 27 Nm (20 lb. ft.). 9. Install the fuel pipe clamp bolt. Tighten Bolt to 12 Nm (106 lb. in.). Important: Apply a few drops of clean engine oil to the vent hose and the air cleaner resonator before installing. 10. Install the crankcase vent hose to bottom of the air cleaner resonator. 11. Install the air cleaner resonator (2) to throttle body (3). Tighten Clamp to throttle body 4-5 Nm (35-44 lb. in.). 12. Install the air cleaner resonator attaching bolts (1). Tighten Bolts to 10 Nm (89 lb. in.). 13. Air cleaner outlet duct to air cleaner resonator. Tighten Clamp to 4-5 Nm (35-44 lb. in.). 14. Install the negative battery cable. 15. Inspect for fuel leaks through the following steps: 1. Turn the ignition switch to the ON position for two seconds. 2. Turn the ignition switch to the OFF position for ten seconds. 3. Turn the ignition switch to the ON position. 4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation FUEL FEED AND RETURN PIPES / HOSES The fuel feed and return pipes and hoses carry fuel from the fuel sender assembly to the fuel rail assembly. With some engines an accumulator is attached to the fuel feed pipe to absorb pulsations that are generated by the injectors cycling. NYLON FUEL PIPES Nylon fuel pipes are designed to perform the same job as the steel or rubber fuel pipes they replace. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are two sizes used: 3 / 8" ID for the fuel feed, and 5 / 16" ID for the fuel return. Pipes that are exposed to chafing, high temperature or vibration are protected with heat resistant rubber hose and / or corrugated plastic conduit. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns. However, if forced into sharp bends, nylon pipes will kink and restrict fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Special care should be taken when working on a vehicle with nylon fuel pipes. WARNING: To Reduce the Risk of Fire and Personal Injury: Always cover nylon fuel pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher then 115° C (239° F) for more than one hour, or more than 90° C (194° F) for any extended period. Take care not to nick or scratch the nylon fuel pipes. If damaged, they must be replaced. QUICK-CONNECT FITTINGS Quick-connect type fittings provide a simplified means of installing and connecting fuel system components. There are three types of quick-connect fittings used at different locations in the fuel system. Each type consists of a unique female socket and a compatible male connector. O-rings, located inside the female socket, provide the fuel seal. Integral locking tabs or fingers hold the fittings together. FUEL PIPE O-RINGS Fuel feed and return pipe threaded connections at the fuel rail and fuel filter are sealed with replaceable O-ring seals. These O-rings seals are made of special material, and should only be serviced with the correct service part. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation FUEL FEED AND RETURN PIPES / HOSES The fuel feed and return pipes and hoses carry fuel from the fuel sender assembly to the fuel rail assembly. With some engines an accumulator is attached to the fuel feed pipe to absorb pulsations that are generated by the injectors cycling. NYLON FUEL PIPES Nylon fuel pipes are designed to perform the same job as the steel or rubber fuel pipes they replace. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are two sizes used: 3 / 8" ID for the fuel feed, and 5 / 16" ID for the fuel return. Pipes that are exposed to chafing, high temperature or vibration are protected with heat resistant rubber hose and / or corrugated plastic conduit. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns. However, if forced into sharp bends, nylon pipes will kink and restrict fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Special care should be taken when working on a vehicle with nylon fuel pipes. WARNING: To Reduce the Risk of Fire and Personal Injury: Always cover nylon fuel pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher then 115° C (239° F) for more than one hour, or more than 90° C (194° F) for any extended period. Take care not to nick or scratch the nylon fuel pipes. If damaged, they must be replaced. QUICK-CONNECT FITTINGS Quick-connect type fittings provide a simplified means of installing and connecting fuel system components. There are three types of quick-connect fittings used at different locations in the fuel system. Each type consists of a unique female socket and a compatible male connector. O-rings, located inside the female socket, provide the fuel seal. Integral locking tabs or fingers hold the fittings together. FUEL PIPE O-RINGS Fuel feed and return pipe threaded connections at the fuel rail and fuel filter are sealed with replaceable O-ring seals. These O-rings seals are made of special material, and should only be serviced with the correct service part. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5642 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5643 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5644 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5645 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5646 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 5647 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair Fuel Tank Unit: Service and Repair Removal Procedure Caution: To reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the negative battery cable. 2. Relieve system fuel pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Filter/Fuel Pressure Release 3. Drain fuel tank. Refer to Draining Fuel Tank. 4. Remove the fuel tank. Refer to Fuel Tank/Service and Repair. Important: ^ The modular fuel sender assembly may spring up from its position. ^ When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one. ^ Carefully discard the reservoir fuel into an approved container. 5. While holding the modular fuel sender assembly down, remove the snap ring from designated slots located on the retainer. Installation Procedure 1. Install a new O-ring on modular fuel sender (3) to tank. 2. Align tab on front of sender (2) with slot on front of retainer snap ring. 3. Slowly apply pressure to top of spring loaded sender until sender aligns flush with retainer on tank. Important: Be sure that the snap ring is fully seated within the tab slots. 4. Insert snap ring (1) into designated slots. 5. Install the fuel tank. Refer to Fuel Tank. 6. Lower vehicle. 7. Refill tank. 8. Inspect for fuel leaks through the following steps: 8.1. Turn the ignition to the ON position for two seconds. 8.2. Turn the ignition to the OFF position for ten seconds. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Page 5651 8.3. Turn the ignition to the ON position. 8.4. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Valve Attaching Screws ................................................................................................................ .................................................... 3.0 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 5655 Idle Speed/Throttle Actuator - Electronic: Locations Front Right Of Engine Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 5656 Motor Idle Air Control Valve Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 5657 Idle Speed/Throttle Actuator - Electronic: Description and Operation Purpose The throttle body (1) assembly is attached to the intake manifold. The throttle body is used to control air flow into the engine, thereby controlling engine output. The throttle valve within the throttle body is opened by the driver through the accelerator controls. During engine idle, the throttle valve is almost closed, and air flow control is handled by the Idle Air Control (IAC) (3) .The throttle body also provides the location for mounting the Throttle Position ( TP) (2) sensor and provides a manifold vacuum source for various components. Vacuum ports are located at the throttle valve to generate vacuum signals needed by various components. Operation Engine idle speed is controlled by the PCM through the IAC valve (1) mounted on the throttle body. The PCM sends voltage pulses to the IAC valve motor windings causing the IAC valve pintle (3) to move IN (toward the seat) or OUT (away from the seat) a given distance (a step or count) for each pulse. The commanded location (steps away from the seated position) can be observed as a number of counts displayed on a scan tool. The pintle movement controls the airflow around the throttle valve (2), which in turn, controls engine idle speed: Pintle Extended=Decrease RPM=Lower Counts. Pintle Retracted=Increase RPM=Higher Counts. The controlled or desired idle speed for all engine operating conditions is programmed into the EEPROM of the PCM. The programmed engine speeds are based on coolant temperature, park/neutral switch status, vehicle speed, battery voltage, and A/C refrigerant pressure (if equipped). The PCM learns the proper IAC valve positions to achieve warm, stabilized idle speeds (RPM), desired for the various conditions (P/N or Drive, A/C ON or OFF, if equipped). This information is stored in PCM Keep Alive memories (information is retained after ignition is OFF). All other IAC valve positioning is calculated based on these memory values. As a result, engine variations due to wear, and variations in minimum throttle valve position (within limits) do not affect engine idle speeds. This system provides correct idle control under all conditions. This also means that disconnecting power to the PCM can result in incorrect idle control or the necessity to partially depress the accelerator when starting, until the PCM relearns idle control. ^ Engine idle speed is a function of total airflow into the engine based on IAC valve pintle position plus throttle valve opening plus calibrated vacuum loss through accessories. ^ The minimum throttle valve position is set at the factory with a stop screw. This setting allows enough air flow by the closed throttle valve to cause the IAC valve pintle to be positioned a calibrated number of steps (counts) from the seat during controlled idle operation. The minimum throttle valve position for this engine is not the same as the minimum idle speed associated with other fuel injected engines. The throttle stop screw is filled at the factory following an adjustment. Important: Do Not try to remove the filler and readjust the stop screw. Misadjustment may set a DTC P0506 or a DTC P0507. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 5658 Idle Speed/Throttle Actuator - Electronic: Service and Repair Removal Procedure 1. Remove the IAC valve electrical connector. 2. Remove the IAC valve attaching screws (1). Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. 3. Remove the IAC valve assembly (2). ^ Clean IAC valve O-ring sealing surface, pintle valve seat, and air passage. ^ The IAC valve may be cleaned, using GM cleaner 1052626 or GM X-66A. Use a shop towel or parts cleaning brush to remove heavy deposits. ^ Shiny spots on the pintle or seat are normal, and do not indicate misalignment or a bent pintle shaft. ^ Whenever air passage have heavy deposits, remove throttle body for complete cleaning. ^ Inspect IAC valve O-ring for cuts, cracks, or distortion. Replace if damaged. ^ Whenever installing a new IAC valve, be sure to replace it with an identical part. IAC valve pintle shape and diameter are designed for the specific application. Installation Procedure 1. Lubricate IAC valve O-ring (3) with clean engine oil. 2. Install the IAC valve assembly (2). 3. Install the IAC valve attaching screws (1). Tighten the IAC valve attaching screws to 3.0 Nm (27 lb. in.). 4. Install the electrical connector. 5. Install the reset IAC valve pintle position: 5.1. Turn ignition switch to the ON position (engine OFF). 5.2. Turn ignition OFF for ten seconds. 5.3. Start engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 Fuel Pump Relay: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 5699 Fuel Pump Relay: Service and Repair Fuel Pump Relay Removal Procedure 1. Remove the relay center cover. 2. Remove the Fuel Pump Relay. Installation Procedure 1. Install the Fuel Pump Relay. 2. Install the relay center cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 Air Flow Meter/Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations LH Rear Of Transaxle LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5742 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5776 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5777 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5778 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Attaching Bolts .............................................................................................................. ................................................... 6.5 Nm (58 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 5782 Throttle Body: Description and Operation Throttle Body GENERAL DESCRIPTION The throttle body (1) assembly is attached to the intake manifold. The throttle body is used to control air flow into the engine, thereby controlling engine output. The throttle valve within the throttle body is opened by the driver through the accelerator controls. During engine idle, the throttle valve is almost closed, and air flow control is handled by the Idle Air Control (IAC) (3) .The throttle body also provides the location for mounting the Throttle Position (TP) sensor (2) and provides a manifold vacuum source for various components. Vacuum ports are located at the throttle valve to generate vacuum signals needed by various components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 5783 Throttle Body: Service and Repair Resonator REMOVAL PROCEDURE 1. Remove the negative battery cable. 2. Remove the air cleaner resonator (2) from throttle body (3). 3. Remove the electrical connectors from IAC valve and TP sensor. 4. Remove the vacuum hoses at throttle body (3). 5. Remove the throttle, cruise, and transmission control cables. 6. Remove the accelerator cable bracket (2). 7. Remove the MAP sensor. 8. Remove the throttle body attaching bolts (1). 9. Loosen throttle body from manifold. INSTALLATION PROCEDURE The EVAP canister may have released carbon particles which may have caused this parts failure. Check the EVAP canister for carbon before returning to the vehicle to service. 1. Install the throttle body (3). 2. Install the accelerator cable bracket (2). 3. Install the MAP sensor. 4. Install the throttle body attaching bolts (1). Tighten bolts to 6.5 Nm (58 lb. in.). 5. Install the throttle, cruise, and transmission control cables to throttle body. 6. Install the vacuum hoses to throttle body. 7. Install the electrical connectors to IAC valve (2) and TP sensor (6). 8. Install the air cleaner resonator (2) to throttle body (3). Important: With the engine OFF, check to see that the accelerator pedal is free, by depressing the pedal to the floor and releasing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 5784 9. Install the negative battery cable. 10. Reset IAC valve pintle position: a. Turn ignition switch to the ON position (engine OFF). b. Turn ignition OFF for ten seconds. c. Start engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Bracket Bolt and Nuts ............................................................................................................................................................. 25 Nm (18 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Control Cable Replacement Throttle Cable/Linkage: Service and Repair Accelerator Control Cable Replacement Removal Procedure 1. Left sound insulator. 2. Release cable retainer from lever assembly. 3. Depress cable tangs and push forward toward engine compartment. 4. Remove the accelerator cam splash shield. 5. Remove the engine accelerator control cable out of bracket. 6. Depress tangs on cable through cable throttle body bracket. 7. Remove the cable from vehicle. Installation Procedure 1. Route cable (1) through cable bracket (4). 2. Press cable upward through bracket. Ensure tangs expand and properly seat. 3. Install the engine accelerator control cable to cam. 4. Install the accelerator cam splash shield. 5. Install the cable to cowl making sure tangs fully expand and seat. 6. Slip accelerator cable through slot in rod of accelerator pedal and install retainer in rod, being sure it is seated. 7. Ensure cable is completely seated in throttle cam past retaining clips. Important: Flexible components (hoses, wires, conduits, etc.) must not be routed within 50 mm (2.0 in) of moving parts of accelerator linkage outboard of support unless routing is positively controlled. 8. Check for correct opening and closing positions by operating accelerator pedal. Make sure that the throttle valve reaches wide-open throttle position. If it does not, inspect for damaged or bent brackets, lever. 9. Install the left sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Control Cable Replacement > Page 5790 Throttle Cable/Linkage: Service and Repair Accelerator Cable Bracket Removal Procedure 1. Remove the cross slug (3) from throttle body slot. 2. Depress tangs and remove cable (1). 3. Remove the bolts (1) to throttle body (3). 4. Remove the bracket (2). Installation Procedure 1. Install the bracket (2) to throttle body (3). 2. Install the bolts (1). Tighten the bolts to 6.5 Nm (58 lb. in.). 3. Install the cable (1) to bracket, making certain tangs fully expand in bracket. 4. Install the cross slug (3) into throttle body slot. Important: Flexible components (hoses, wires, conduits, etc.) must not be routed within 50 mm (2.0 in.) of moving parts of accelerator linkage outboard of support unless routing is positively controlled. 5. Check for correct opening and closing positions by operating accelerator pedal. Make sure that the throttle valve reaches wide-open throttle position. If it does not, inspect for damaged or bent brackets, lever, or other components; or, for poor carpet fit under the accelerator pedal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Screws ......................................................................................................... ......................................................... 3 Nm (27 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5794 Throttle Position Sensor: Locations LH Front Of Engine Front Right Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Throttle Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5828 Throttle Position Sensor: Description and Operation TP Sensor Service Purpose The Throttle Position (TP) sensor (2) is a potentiometer connected to the throttle shaft on the throttle body. The TP sensor electrical circuit consists of a 5 volt supply line and a ground line, both provided by the Powertrain Control Module (PCM), and a signal line to the PCM. By monitoring the voltage on this signal line, the PCM can calculate throttle position angle in a percentage. As the throttle valve angle is changed (accelerator pedal moved), the output of the TP sensor also changes. At a closed throttle position, the output of the TP sensor is low (approximately 0.6 volt). As the throttle valve opens, the output increases so that, at wide open throttle, the output voltage should be near 5 volts. Operation The PCM can determine fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor can cause intermittent bursts of fuel from the injectors and an unstable idle, because the PCM thinks the throttle is moving. A high or low voltage problem in the TP sensor circuits should set either a DTC P0122 or DTC P0123. The PCM also has the capability of setting a DTC P0121 if the sensor is reading out of range. Once a diagnostic trouble code is set, the PCM will use a default value for the TP sensor, and some vehicle performance will return. See TP Sensor for 2.4L or TP Sensor for replacement of the TP sensor. The TP sensor is not adjustable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5829 Throttle Position Sensor: Testing and Inspection A scan tool displays throttle position in volts. The scan tool should display 0.20 volt to 0.90 volt with the throttle closed (as at idle) and ignition ON. Voltage should increase at a steady rate as the throttle opens. Voltage should be near 5.0 volts at wide open throttle. A scan tool also has the ability to display the throttle angle and should display 0% when the throttle is closed, and increase smoothly to 100% at WOT. The Powertrain Control Module (PCM) has the ability to auto-zero the TP sensor voltage if it is below about 0.90 volt (900 mV). This means that any voltage less than 0.90 volt will be determined by the PCM to be 0% throttle. A fault in the TP sensor or circuit should set a DTC P0122 or P0123. A stuck sensor will set a DTC P0121. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 5830 Throttle Position Sensor: Service and Repair TP Sensor Service Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Remove the throttle body. 3. Remove the TP sensor attaching screws (1) and retainers. 4. Remove the TP sensor (2). Installation Procedure 1. With the throttle valve in the normal closed (idle) position, install the throttle position sensor (2) on the throttle body assembly. Important: Install the new TP sensor attaching screws when replacing TP sensor. 2. Install the retainers and the two TP sensor screws (1). Tighten the screws to 3 Nm (27 lb. in.). 3. Install the throttle body. Refer to Throttle Body Assembly. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The ignition timing is completely controlled by the Powertrain Control Module (PCM). No timing reference marks are provided. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5847 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5848 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5882 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5883 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5887 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5921 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5922 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Coil and Ignition Housing - Characteristic Conditions Ignition Coil: Technical Service Bulletins Coil and Ignition Housing - Characteristic Conditions File in Section: 6E - Engine Fuel & Emission Bulletin No.: 67-65-34 Date: November, 1996 INFORMATION Subject: Coil and Ignition Housing Characteristic Conditions Models: 1988-97 Buick Skylark 1988-93 Chevrolet Beretta 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1987-91 Oldsmobile Calais 1990-91 Oldsmobile Cutlass Supreme 1992-97 Oldsmobile Achieva 1997 Oldsmobile Cutlass 1988-97 Pontiac Grand Am 1990-91 Pontiac Grand Prix 1995-97 Pontiac Sunfire with Quad 4 and LD9 Twin Cam Engines (VINs A, D, 3, T - RPOs LG0, LD2, L40, LD9) A high percentage of ignition coils and ignition coil housings from the above vehicles returned under the corporate warranty return program have been tested with no trouble found. A review of warranty repair orders has indicated that ignition coils and housings are being replaced for conditions that are characteristic of this ignition system, and not indicative of a part failure. A large number of ignition coil housings from 1995 and 1996 Quad 4 and Twin Cam engines have, after a period of use, a characteristic marking often Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Coil and Ignition Housing - Characteristic Conditions > Page 5927 referred to on repair orders as "tracking". This "tracking" is a characteristic of the high voltage distribution through the coil housing and can easily be wiped away with a damp rag. These false "tracks" are most often seen on the bottom of the housing between the secondary ignition terminals. (See Figure 1) Actual "tracking" from a high voltage arc, is characterized by damage to the coil housing with black residue or carbon imbedded in housing material. This type of damage cannot be wiped away to any significant degree and can often be felt as well as seen. There have also been numerous ignition coils replaced due to a condition often described on repair orders as a "burn" or "burned". All Quad 4 and Twin Cam ignition coils have a pair of welds on the metal portion nearest the connection for the primary wiring. These welds are made after the coil is assembled and in some cases the welding process leaves a black mark or some debris on the coil. This debris can be wiped away with a damp rag leaving behind a small black mark on the corner of the coil nearest the weld. This weld process in no way degrades the function of the coil and is a natural part of the manufacturing process. (See Figure 2) Ignition parts should be diagnosed by using the information contained in Section 6E (Driveability and Emissions or Engine Controls) of the appropriate Service Manual, keeping these characteristic conditions in mind. Always follow the Strategy Based Diagnostic method for ignition components, using appropriate resistance values and informed visual inspection if necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 5928 Ignition Coil: Specifications Ignition Control Module Cover Bolts ........................................................................................................................................................ 22 Nm (16 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 5929 Ignition Coil: Description and Operation Description The Electronic Ignition (EI) system consists of two separate ignition coils, an electronic Ignition Control Module (ICM) and a secondary conductor housing mounted to an aluminum cover plate. A Crankshaft Position (CKP) sensor, related connecting wires and the Ignition Control (IC) portion of the PCM make up the remainder of the system. Operation A distributorless ignition system, such as this one, uses a waste spark method of spark distribution. Each cylinder is paired with the cylinder that is opposite it (1-4 or 2-3). The spark occurs simultaneously in the cylinder coming up on the compression stroke and in the cylinder coming up on the exhaust stroke. The cylinder on the exhaust stroke requires very little of the available energy to fire the spark plug. The remaining energy will be used as required by the cylinder on the compression stroke. The same process is repeated when the cylinders reverse roles. It is possible in a no load condition for one plug to fire even through the spark plug lead from the same coil is disconnected from the other spark plug. The disconnected spark plug lead acts as one plate of a capacitor, with the engine being the other plate. These two capacitor plates are charged as a current surge (spark) jumps across the gap of the connected spark plug. The plates are then discharged as the secondary energy is dissipated in an oscillating current across the gap of the spark plug still connected. Because of the direction of current flow in the primary winding and thus, in the secondary winding, one plug fires from the center electrode to the side electrode while the other fires from side electrode to center electrode. This system utilizes the IC signal from the PCM to control spark timing. To properly control ignition timing, the PCM also relies on the following information: ^ Engine load (manifold pressure or vacuum). ^ Engine coolant temperature. ^ Intake air temperature. ^ Crankshaft position. ^ Engine speed (RPM). ^ Spark knock indication. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 5930 Ignition Coil: Service and Repair Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electronic Ignition Control Module (ICM) 11 pin harness connector. 3. Remove the ignition coil and the electronic ignition control module assembly to camshaft housing bolts. Notice: If boots adhere to spark plugs, use tool J 36011 to remove by first twisting and then pulling upward on retainers. Reinstall boots and retainers on ignition coil housing secondary terminals. Boots and retainers must be in place on ignition coil housing secondary terminals prior to ignition coil and electronic ignition control module assembly installation or ignition control system damage may result. 4. Remove the ignition coil and the electronic ignition control module assembly from the engine. Installation Procedure 1. Install the spark plug boots and the retainers to the housing. 2. Install the ignition coil and the electronic ignition control module assembly to the engine while carefully aligning the boots to the spark plug terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 5931 Important: ICM cover bolts must be installed with the isolator washers with the rubber side facing down. 3. Install the ignition coil and the electronic ignition control module assembly to the cam housing bolts, after coating the threads with P/N 1052080 or equivalent. Tighten the ICM cover bolts to 22 Nm (16 lb. ft.). 4. Connect the electronic ICM 11 pin harness connector. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM No Start Condition, Ignition Module Ignition Control Module: Customer Interest PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM No Start Condition, Ignition Module > Page 5940 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM No Start Condition, Ignition Module > Page 5941 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: All Technical Service Bulletins PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 5947 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 5948 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 5949 Ignition Control Module: Specifications Module to Cover Screws ..................................................................................................................... ........................................................ 4 Nm (35 lb. in.) Housing to Cover Screws ................................ ............................................................................................................................................ 4 Nm (35 lb. in.) Ignition Control Module Assembly to Cam Housing Bolts ........................................................................................................................ 22 Nm (16 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 5952 Ignition Control Module: Connector Locations Left Rear Of Transaxle LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5953 Ignition Control Module: Diagrams Electronic Ignition Control Module: C1 And C2 Electronic Ignition Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5954 Ignition Control Module: Description and Operation The Ignition Control Module (ICM) receives the Ignition Control (IC) signals from the PCM which in turn triggers the corresponding ignition coils. Since the PCM controls spark timing and ignition control during crank and run, there is no bypass mode. The ICM is not repairable. When an ICM is replaced, transfer the remaining components to the new module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5955 Ignition Control Module: Service and Repair Ignition Control Module (ICM) Removal Procedure Tools Required J 36011 Spark Plug Removal Tool. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. Disconnect the negative battery cable. 2. Remove the accelerator and cruise control cables out of the hold down clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5956 3. Remove the fuel line retainer clip bolt. 4. Disconnect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5957 5. Remove the Ignition Coil and the Electronic Ignition Control Module (ICM) assembly to camshaft housing bolts. Notice: Spark plug boots often adhere to the spark plugs. Use tool J 36011 in order to remove by first twisting and then pulling upward on retainers. Reinstall the boots and the retainers on the ignition coil housing secondary terminals. The boots and the retainers must be in place on the ignition coil housing secondary terminals prior to the ignition coil and the electronic ignition control module assembly installation or ignition control system damage may result. 6. Remove the Ignition Coil and Electronic Ignition Control Module (ICM) assembly from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5958 7. Remove the housing to cover screws. Important: When removing the housing from the cover make sure the ground strap stays in place. 8. Disconnect the coil harness electrical connector from the Ignition Control Module. 9. Remove the housing from the cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5959 10. Remove the Ignition Control Module to cover screws. 11. Remove the Ignition Control Module from the cover. Installation Procedure Important: DO NOT wipe grease from the module or coil if the same module is to be replaced. If a new module is to be installed, a package of silicone grease will be included with it. Spread the grease on the metal face of the module and on the cover where the module seats. This grease is necessary for module cooling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5960 1. Install the Ignition Control Module to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the Ignition Control Module to cover screws. Tighten Tighten the screws to 4 Nm (35 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5961 3. Install the ground strap (if the ground strap is not already installed). 4. Connect the Ignition Coil(s) electrical connector to the Ignition Control Module. Important: When installing the housing to the cover make sure the ground strap stays in place. 5. Install the housing to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5962 6. Install the housing to cover screws. Tighten Tighten the housing to cover screws 4 Nm (35 lb in). 7. Install the spark plug boots and the retainers to the housing (if the spark plug boot and retainer is not already installed). 8. Install the Ignition Coil and Electronic Ignition Control Module assembly to the engine while carefully aligning the spark boots to the spark plug terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5963 9. Install the ignition coil and the electronic ignition control module assembly to camshaft housing bolts after coating the threads with Sealant LOCTITE GM 12346004 or equivalent. Tighten Tighten the bolts to 22 Nm (16 lb ft). Important: The ICM cover bolts must be installed with isolator washers with the rubber side facing down. 10. Connect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5964 11. Install the fuel line retainer clip bolt. 12. Install the accelerator and cruise control cables into the hold down clip. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls - Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 5969 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 5972 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 5973 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 6007 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 6008 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: Customer Interest PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6018 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6019 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module Ignition Control Module: All Technical Service Bulletins PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6025 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6026 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 6027 Ignition Control Module: Specifications Module to Cover Screws ..................................................................................................................... ........................................................ 4 Nm (35 lb. in.) Housing to Cover Screws ................................ ............................................................................................................................................ 4 Nm (35 lb. in.) Ignition Control Module Assembly to Cam Housing Bolts ........................................................................................................................ 22 Nm (16 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 6030 Ignition Control Module: Connector Locations Left Rear Of Transaxle LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6031 Ignition Control Module: Diagrams Electronic Ignition Control Module: C1 And C2 Electronic Ignition Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6032 Ignition Control Module: Description and Operation The Ignition Control Module (ICM) receives the Ignition Control (IC) signals from the PCM which in turn triggers the corresponding ignition coils. Since the PCM controls spark timing and ignition control during crank and run, there is no bypass mode. The ICM is not repairable. When an ICM is replaced, transfer the remaining components to the new module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6033 Ignition Control Module: Service and Repair Ignition Control Module (ICM) Removal Procedure Tools Required J 36011 Spark Plug Removal Tool. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. Disconnect the negative battery cable. 2. Remove the accelerator and cruise control cables out of the hold down clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6034 3. Remove the fuel line retainer clip bolt. 4. Disconnect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6035 5. Remove the Ignition Coil and the Electronic Ignition Control Module (ICM) assembly to camshaft housing bolts. Notice: Spark plug boots often adhere to the spark plugs. Use tool J 36011 in order to remove by first twisting and then pulling upward on retainers. Reinstall the boots and the retainers on the ignition coil housing secondary terminals. The boots and the retainers must be in place on the ignition coil housing secondary terminals prior to the ignition coil and the electronic ignition control module assembly installation or ignition control system damage may result. 6. Remove the Ignition Coil and Electronic Ignition Control Module (ICM) assembly from the engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6036 7. Remove the housing to cover screws. Important: When removing the housing from the cover make sure the ground strap stays in place. 8. Disconnect the coil harness electrical connector from the Ignition Control Module. 9. Remove the housing from the cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6037 10. Remove the Ignition Control Module to cover screws. 11. Remove the Ignition Control Module from the cover. Installation Procedure Important: DO NOT wipe grease from the module or coil if the same module is to be replaced. If a new module is to be installed, a package of silicone grease will be included with it. Spread the grease on the metal face of the module and on the cover where the module seats. This grease is necessary for module cooling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6038 1. Install the Ignition Control Module to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the Ignition Control Module to cover screws. Tighten Tighten the screws to 4 Nm (35 lb in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6039 3. Install the ground strap (if the ground strap is not already installed). 4. Connect the Ignition Coil(s) electrical connector to the Ignition Control Module. Important: When installing the housing to the cover make sure the ground strap stays in place. 5. Install the housing to the cover. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6040 6. Install the housing to cover screws. Tighten Tighten the housing to cover screws 4 Nm (35 lb in). 7. Install the spark plug boots and the retainers to the housing (if the spark plug boot and retainer is not already installed). 8. Install the Ignition Coil and Electronic Ignition Control Module assembly to the engine while carefully aligning the spark boots to the spark plug terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6041 9. Install the ignition coil and the electronic ignition control module assembly to camshaft housing bolts after coating the threads with Sealant LOCTITE GM 12346004 or equivalent. Tighten Tighten the bolts to 22 Nm (16 lb ft). Important: The ICM cover bolts must be installed with isolator washers with the rubber side facing down. 10. Connect the Electronic Ignition Control Module (ICM) 11 pin harness electrical connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 6042 11. Install the fuel line retainer clip bolt. 12. Install the accelerator and cruise control cables into the hold down clip. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications CMP Sensor Bolt ................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 6047 Camshaft Position Sensor: Locations Front Right Of Engine Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 6048 Left Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Camshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6082 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (1) is used to correlate crankshaft to camshaft position so that the Powertrain Control Module (PCM) can determine which cylinder is ready to be fueled by the injector. The CMP sensor is also used to determine which cylinder is misfiring when misfire is present. If the PCM receives an intermittent signal from the CMP, then the CMP Resync Counter will increment. When the PCM cannot use the information from the CMP sensor, a DTC is set and the PCM will fuel the engine using the Alternating Synchronous Double Fire (ASDF) method. This sensor has no effect on the Electronic Ignition (EI) system. A fault in the CMP sensor circuits will cause a DTC P0341 or P0342. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 6083 Camshaft Position Sensor: Service and Repair Removal Procedure 1. Disconnect the CMP sensor harness connector at the sensor. 2. Remove the CMP sensor bolt (2). 3. Remove the CMP sensor (1) from the camshaft housing (3). Installation Procedure Important: Inspect sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate new O-ring with engine oil before installing. 1. CMP sensor (1) into camshaft housing (3). 2. CMP sensor bolt (2). Tighten the CMP sensor bolt to 10 Nm (88 lb. in.). 3. Sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications CKP Sensor Bolt .................................................................................................................................. ..................................................... 10 Nm (88 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 6087 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Crankshaft Position Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6121 Crankshaft Position Sensor: Description and Operation PURPOSE This system uses a magnetic Crankshaft Position (CKP) sensor, mounted remotely from the Ignition Control Module (ICM), which protrudes into the block within approximately 0.050 inch from the crankshaft reluctor. The image shows a typical sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots machined in it, six of which are equally spaced 60 degrees apart. A seventh slot is spaced 10 degrees from one of the other slots and serves to generate a "sync-pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. The signal is necessary for the Powertrain Control Module (PCM) to determine when to activate the fuel injectors. OPERATION Based on the CKP sensor pulses, the CKP sensor sends 7X reference signals to the PCM which is used to indicate crankshaft position and engine speed. The CKP sensor continues to send these reference pulses to the PCM at a rate of seven times per 360 degrees of crankshaft rotation. This signal is called the 7X reference because it occurs 7 times per crankshaft revolution. By comparing the time between pulses, the PCM can recognize the pulse representing the seventh slot (sync pulse) which starts the calculation of ignition coil sequencing. The second crank pulse following the "sync pulse" signals the PCM to fire the #2-3 ignition coil and the fifth crank pulse signals the PCM to fire the #1-4 ignition coil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6122 Crankshaft Position Sensor: Service and Repair Crankshaft Sensor Removal Procedure 1. Disconnect the CKP sensor harness connector at the sensor. 2. Remove the CKP sensor to block bolt. 3. Remove the CKP sensor from the engine. Installation Procedure Important: Inspect the sensor O-ring for wear, cracks or leakage. Replace if necessary. Lubricate the new O-ring with engine oil before installing. 1. Install the CKP sensor into the block. 2. Install the CKP sensor to block bolt. Tighten the bolt to 10 Nm (88 lb. in.). 3. Connect the CKP sensor harness connector. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 6132 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 6133 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 6134 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 6144 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 6145 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 6146 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6152 Ignition Switch Lock Cylinder: Service and Repair Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Engine Controls - Revised Knock Sensor Data Table Knock Sensor: Technical Service Bulletins Engine Controls - Revised Knock Sensor Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-52 Date: July, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Revised Knock Sensor Noise Channel Scan Tool Information Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Grand Am, Sunfire 1997 Chevrolet and GMC S/T Models with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the Engine Data 1 Scan Tool Data table for the following Service Manuals: ^ 1997 GMP/97-J-2, pages 11 and 417 ^ 1997 GMP/97-N-2, page 9 ^ 1997 GMP/97-L/N-2, page 9 ^ 1997 GMP/97-S/T-2, page 416 In the Engine 1 Scan Tool Data table, the KS Noise Channel parameter will display a number from 0-255. This parameter is a rolling counter. When engine knock is present, the KS Noise Channel parameter should increment to 255, reset to 0 and start incrementing again. If no engine knock is present, the KS Noise Channel parameter does not increment. In the Engine 1 Scan Tool Definitions, the range of the KS Noise channel should indicate the 0-255 rolling counter. Please mark up your Service Manual with these revisions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Technical Service Bulletins > Page 6157 Knock Sensor: Specifications Knock Sensor ...................................................................................................................................... ....................................... 16-22 Nm (143-196 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations Knock Sensor: Component Locations Detonation Sensor KNOCK SENSOR KS (DETONATION SENSOR) LH Rear Of Transaxle The Knock Sensor (KS) is located on the rear center of engine. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 6160 LH Side Of Engine Compartment Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 6161 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Knock Sensor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 6195 Knock Sensor: Description and Operation Purpose Varying octane levels in the gasoline can cause a detonation in performance engines. Detonation is sometimes called a spark knock. A spark knock causes the pistons and the rings to vibrate and rattle, sometimes producing a knocking sound. In order to control a spark knock, a Knock Sensor (KS) is used. This system is designed to retard the spark timing up to 15 degrees in order to reduce a spark knock in the engine. This allows the engine to use a maximum spark advance in order to improve driveability and fuel economy. The PCM uses information from the MAP and coolant sensor in addition to the RPM in order to calculate the spark advance as follows: ^ Low MAP output voltage equals more spark advance. ^ Cold engine equals more spark advance. ^ High MAP output voltage equals less spark advance. ^ Hot engine equals less spark advance. A low MAP output or high resistance in the Engine Coolant Temperature (ECT) sensor circuit could cause detonation. A high MAP output or low resistance in the coolant sensor circuit could cause poor performance. Operation The Knock Sensor (KS) system has two major components: 1. The KS module. 2. The Knock Sensor (KS). The KS module is an integral part of the PCM. The KS module is not serviceable The knock sensor is mounted into the engine block near the cylinders. The knock sensor produces an AC voltage which increases with the severity of the knock. This signal voltage inputs to the Powertrain Control Module (PCM). The PCM then adjusts the Ignition Control (IC) timing to reduce spark knocking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 6196 Knock Sensor: Service and Repair Knock Sensor Removal Procedure 1. Disconnect the negative battery cable from the battery. 2. Raise the vehicle and suitably support. 3. Disconnect the KS wiring harness connector from the knock sensor. 4. Remove the knock sensor (1) from the engine block. Installation Procedure 1. Clean the threads thoroughly. Install the knock sensor (1) into the engine block. Tighten the knock sensor to 19 Nm (170 lb in). 2. Connect the KS wiring harness connector to the knock sensor. 3. Lower the vehicle. 4. Connect the negative battery cable to the battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition - Revised Spark Plug Gap Spark Plug: Technical Service Bulletins Ignition - Revised Spark Plug Gap File In Section: 6E - Engine Fuel & Emission Bulletin No.: 77-65-11A Date: May, 1997 INFORMATION Subject: Production Spark Plug Gap Change Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN T - RPO LD9) This bulletin is being revised to add Chevrolet Malibu to models. Please discard Corporate Bulletin Number 77-65-11 (Section 6E - Engine Fuel & Emission). A change in spark plug gap has been made to reduce spark plug fouling during repeated low speed operation of these vehicles at assembly plants, rail heads and dealer/retailer unloading points. The electrode gap of the production spark plugs has been reduced from 1.52 mm (0.060 in) to 1.27 mm (0.050 in). If a spark plug is removed to perform a service procedure and the gap is found to be 1.52 mm (0.060 in) and the spark plugs are functioning normally, do not change the spark plugs. Original equipment spark plugs will have the production part number imprinted on the ceramic insulator. The 1.52 mm (0.060 in) electrode gap spark plug will have a production part number of 25164044 and the 1.27 mm (0.050 in) electrode gap spark plug will have a production part number of 25312636. The service spark plug part number for all 1997 LD9 engines is 25164048 with an electrode gap of 1.27 mm (0.050 in). Important: Do not mix spark plugs with different electrode gaps on the same engine. If it becomes necessary to change a spark plug in any of these vehicles equipped with spark plugs that have a 1.52 mm (0.060 in) gap, replace all four spark plugs with GM Part Number 25164048 with the electrode gap set at 1.27 mm (0.050 in). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 0.060 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 6203 Spark Plug: Specifications Spark Plug Torque 13 lb. ft. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 6204 Spark Plug: Application and ID Spark Plug Identification Chart Spark Plugs: GM Part # 24161677 A-C Type 41-928 Gapped @ 1.52mm (0.060 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 6205 Spark Plug: Description and Operation NOTE: This engine has aluminum cylinder heads. Allow the engine to cool before removing spark plugs, or the spark plug threads in the cylinder head may be damaged. - This engine uses tapered seat resistor type spark plugs without gaskets. Always replace plugs with the same spark plug as listed. DESCRIPTION Normal service is assumed to be a mixture of idling, slow speed, and high speed driving. Occasional or intermittent highway driving is needed for good spark plug performance because it gives increased combustion heat that bums away any excess deposits of carbon or oxides that have built up from frequent idling or continual stop-and-go driving. Spark plugs are protected by an insulating boot made of special heat-resistant material which covers the spark plug terminal and extends downward over a portion of the plug insulator. These boots prevent flash-over which causes engine mis-firing. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of a high-tension field, and has no effect on ignition performance. Usually it can be detected only in darkness. This discharge may repel dust particles, leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown out between shell and insulator. Spark plugs must operate within certain temperature limits if they are to provide the performance and service life expected. The spark plug selected for an engine is based on the normal service which the engine was designed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 6206 Spark Plug: Testing and Inspection Worn or dirty plugs may give satisfactory operation at idling speed, but under operating conditions they frequently fail. Faulty plugs are indicated in a number of ways: poor fuel economy, power loss, loss of speed, hard starting and general poor engine performance. Spark plugs may also fail due to carbon fouling, excessive gap, or a broken insulator. Fouled plugs Fouled plugs are identified by black carbon deposits. The black deposits are usually the result of slow-speed driving and short runs where sufficient engine operating temperature is seldom reached. Worn pistons, rings, faulty ignition, over-rich air/fuel mixture and spark plugs which are too cold will also result in carbon deposits. Excessive gap Excessive gap wear, on plugs of low mileage, usually indicates the engine is operating at high speeds or loads that are consistently greater than normal or that a plug which is too hot is being used. Electrode wear may also be the result of plug overheating, caused by combustion gases leaking past the threads, due to insufficient spark plug torque or too much spark plug torque. An excessively lean air/fuel mixture will also result in excessive electrode wear. Broken insulator Broken insulators are usually the result of improper installation or carelessness when regapping the plug. Broken upper insulators usually result from a poor fitting wrench or an outside impact. The cracked insulator may not show up right away, but will as soon as oil or moisture penetrates the crack. The crack is usually just below the crimped part of the shell and may not be visible. Broken lower insulators usually result from carelessness when regapping and generally are visible. This type of break may result from the plug operating too "hot," which may happen in periods of high-speed operation or under heavy loads. When regapping a spark plug, always make the gap adjustment by bending the ground (side) electrode. Spark plugs with broken insulators should always be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 6207 Spark Plug: Service and Repair CAUTION: To avoid engine damage, do not remove spark plugs when engine is warm. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Electronic ignition module assembly 4 bolts and connector. 3. Remove by pulling straight up on housing. 4. Use tool J 36011 or equivalent to remove connector assembly(s) if stuck to the spark plugs. - Use tool by first twisting then pulling up on the connector assembly. 5. Remove debris from area around the spark plugs. 6. Remove the spark plugs using a spark plug socket. INSTALL OR CONNECT 1. Adjust spark plug gap to 1.52 mm (0.060 inch) using a round wire type spark plug gap gage. While gapping plug be sure to keep the platinum pads aligned to ensure maximum plug life. 2. Hand start spark plugs into the cylinder head. Tighten Spark plugs to 18 Nm (13 lbs. ft.). 3. Reinstall onto the module assembly any spark plug boot connector assembly that stuck to a spark plug. - Check to be sure spring terminal is inside boot. - Reapply dielectric lubricant to insulator boot. 4. Locate module assembly over spark plugs and push straight down. 5. Clean any loose lubricant that is present on the module assembly to cam housing bolts. 6. Apply threadlocker onto the module assembly to cam housing bolts. CAUTION: Hand start the module assembly to cam housing bolts. Tighten Bolts to 22 Nm (16 lbs. ft.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 6208 7. Electrical connector. 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6220 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6221 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6227 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6228 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6229 Pressure Regulating Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6230 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations LH Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 6237 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 Torque Converter Clutch Solenoid: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Valve body cover. 2. Wiring harness from case electrical connector and leads from pressure switch. 3. Torque converter clutch solenoid bolt to auxiliary valve body. 4. 3rd clutch pressure switch. 5. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. Tighten Tighten to 12 N.m (124 lb. in.). 2. 3rd clutch pressure switch. Tighten Tighten to 12 N.m (124 lb. in.). 3. Torque converter clutch solenoid bolt to auxiliary valve body. Install new "O" ring. Tighten Tighten to 12 N.m (124 lb. in.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6242 Torque Converter Clutch Solenoid: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6243 1. Install the solenoid and O-ring or O-rings. 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The Upshift Indicator is illuminated to indicate optimum shift points for maximum fuel economy. When this light is on, shift transaxle to the next higher gear range, if conditions permit. This indicator is controlled by the IPC as commanded by the PCM via serial data. This telltale will not turn on as result of serial data loss (ignition in OFF/UNLOCK"). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove Pressure switch assembly, (6 bolts). Important Inspect the O-rings for the pressure switch assembly for any damage. INSTALL OR CONNECT 1. Install the pressure switch assembly making sure all O-rings are in place. 2. Torque the 6 bolts holding the pressure switch assembly to 12 N.m (9 lb. ft.). 3. Install the transaxle case side cover. Refer to "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6268 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6269 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6275 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6276 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 6288 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6289 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6290 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6291 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6294 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6295 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6296 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON PROM - Programmable Read Only Memory: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6305 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6306 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module PROM - Programmable Read Only Memory: Customer Interest PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6311 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6312 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6318 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6319 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 99-06-04-053 > Nov > 99 > PROM - Powertrain Control Module Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Powertrain Control Module Reprogramming File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-053 Date: November, 1999 INFORMATION Subject: Powertrain Control Module (PCM) Reprogramming (Do Not Reprogram Using the Same Download Files as Those Already Present in The Control Module) Models: 1990-2000 Passenger Cars and Trucks with Reprogrammable PCM It is strongly recommended to NOT reinstall the same software and/or calibration download file(s) into the powertrain control module as those that are already present in the PCM. There is no technical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfully programmed. A P0601 (Control Module Read Only Memory) Diagnostic Trouble Code would set in memory and the MIL would be illuminated if the controller memory became corrupted. The Techline Information System 2000 (TIS 2000) PC, combined with vehicle information gained through the Tech 2, can determine when an attempt to reprogram a PCM using the same download files (as those already in the control module) is being requested. If this is attempted, the TIS 2000 PC currently displays the following message: Notice: THE CALIBRATION SELECTED IS THE CURRENT CALIBRATION IN THE CONTROL MODULE. PROGRAMMING WITH THE SAME DOWNLOAD FILES IS NOT AN EFFECTIVE REPAIR. SELECT ( YES ) TO CONTINUE PROGRAMMING THE CONTROL MODULE,OR ( NO ) TO CANCEL. Effective in the first quarter of 2000, the TIS 2000 PC will indicate: Important: THE CALIBRATION SELECTED IS ALREADY THE CURRENT CALIBRATION IN THE CONTROL MODULE. REPROGRAMMING WITH THE SAME DOWNLOAD FILE IS NOT ALLOWED. Certain learned values, such as: (but not limited to) ^ fuel trim (previously known as block learn memory), ^ IAC learned position in various park/neutral and air conditioning on/off combinations, ^ certain OBDII diagnostic thresholds, ^ automatic transmission shift adapts will revert back to their unlearned starting point values after a reprogramming event occurs. It is feasible that the engine or transmission might temporarily operate differently after a reprogramming event, until these values are re-learned. Relearning occurs while operating the vehicle through normal driving routines. If the same download files are simply reinstalled, any changes noticed in engine operation will likely disappear in a short amount of time and/or driving distance. Reprogramming the control module with the same download files that already exist in the module will only accomplish a warranty claim for a non-effective repair, and a likely comeback. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - No Start Condition, Ignition Module File In Section: 6E Engine Fuel & Emission Bulletin No.: 77-65-16 Date: May, 1997 Subject: No Start Condition (Reprogram PCM) Models: 1997 Buick Skylark 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Achieva 1997 Pontiac Sunfire, Grand Am with 2.4L Engine (VIN Code T - RPO LD9) Condition Some vehicles with the above condition may exhibit a no start condition caused by ignition module failure. This failure results in a loss of spark to the ignition coil for cylinders 2 and 3. Vehicles Involved Involved are certain 1997 J-Car and N-Car models equipped with the 2.4L (RPO LD9) VIN Engine Code T engine, that fall within the following VIN breakpoints: Cause A voltage feedback condition in the ignition module caused by random voltage spikes in the vehicle electrical system may cause the control circuitry in the Ignition module to be damaged. Correction Install a new Ignition Module, and reprogram the PCM with the revised calibration that prevents the voltage spikes from reaching the ignition module. This calibration is available on CD-ROM # 6 and later versions. Calibration Numbers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6328 Use the correct calibration from the list: Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 77-65-16 > May > 97 > PROM - No Start Condition, Ignition Module > Page 6329 For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6334 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6335 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6336 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6337 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6338 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6339 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6340 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 99-06-04-053 > Nov > 99 > PROM - Powertrain Control Module Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Powertrain Control Module Reprogramming File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-053 Date: November, 1999 INFORMATION Subject: Powertrain Control Module (PCM) Reprogramming (Do Not Reprogram Using the Same Download Files as Those Already Present in The Control Module) Models: 1990-2000 Passenger Cars and Trucks with Reprogrammable PCM It is strongly recommended to NOT reinstall the same software and/or calibration download file(s) into the powertrain control module as those that are already present in the PCM. There is no technical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfully programmed. A P0601 (Control Module Read Only Memory) Diagnostic Trouble Code would set in memory and the MIL would be illuminated if the controller memory became corrupted. The Techline Information System 2000 (TIS 2000) PC, combined with vehicle information gained through the Tech 2, can determine when an attempt to reprogram a PCM using the same download files (as those already in the control module) is being requested. If this is attempted, the TIS 2000 PC currently displays the following message: Notice: THE CALIBRATION SELECTED IS THE CURRENT CALIBRATION IN THE CONTROL MODULE. PROGRAMMING WITH THE SAME DOWNLOAD FILES IS NOT AN EFFECTIVE REPAIR. SELECT ( YES ) TO CONTINUE PROGRAMMING THE CONTROL MODULE,OR ( NO ) TO CANCEL. Effective in the first quarter of 2000, the TIS 2000 PC will indicate: Important: THE CALIBRATION SELECTED IS ALREADY THE CURRENT CALIBRATION IN THE CONTROL MODULE. REPROGRAMMING WITH THE SAME DOWNLOAD FILE IS NOT ALLOWED. Certain learned values, such as: (but not limited to) ^ fuel trim (previously known as block learn memory), ^ IAC learned position in various park/neutral and air conditioning on/off combinations, ^ certain OBDII diagnostic thresholds, ^ automatic transmission shift adapts will revert back to their unlearned starting point values after a reprogramming event occurs. It is feasible that the engine or transmission might temporarily operate differently after a reprogramming event, until these values are re-learned. Relearning occurs while operating the vehicle through normal driving routines. If the same download files are simply reinstalled, any changes noticed in engine operation will likely disappear in a short amount of time and/or driving distance. Reprogramming the control module with the same download files that already exist in the module will only accomplish a warranty claim for a non-effective repair, and a likely comeback. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Reprogram Using Off Board Program Adapter File In Section: 6E - Engine Fuel & Emission Bulletin No.: 73-65-13 Date: March, 1997 INFORMATION Subject: Reprogramming Capability using the Off Board Programming Adapter Models: 1993-97 Passenger Cars and Trucks (Applicable Reprogrammable Vehicles) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6350 The General Motors vehicles contain Electronically Reprogrammable Devices (i.e. PCM, VCM, ECM). These vehicles cannot be programmed through PROM replacement, however service programming capability is available through the Tech 1/1A, Tech 2 and Techline terminals via direct or remote programming. The Environmental Protection Agency (EPA) has requested that all new vehicle manufacturers ensure their dealers/retailers are aware that they are responsible for providing customers access to reprogramming services at a reasonable cost and in a timely manner. Although programming of controllers has become a common service practice at GM dealers/retailers, the EPA has received reports from consumers and the aftermarket repair industry that they were unable to purchase a new (programmed) Electronically Reprogrammable Device (ERD) over-the-counter. As a result, on August 1, 1995, the Federal Government issued a regulation requiring all manufacturers to make available reprogramming to the independent aftermarket by December 1, 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6351 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6352 Today, the Off Board Programming Adapter (OBPA) is used to reprogram ERD's sold over-the-counter. For all practical purposes, the OBPA takes the place of the vehicle when the vehicle is not available. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6353 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6354 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6355 The list of dealerships/retailers currently own the OBPA (see Attachments 1 - 3). These locations are equipped to provide over-the-counter preprogrammed ERD's. The hardware required to perform reprogramming in addition to the OBPA is a Techline terminal, Tech 1/1A and associated cables and adapters. THE TECH 2 SHOULD NOT BE USED WITH THE OBPA AT THIS TIME BECAUSE OF INADEQUATE OBPA GROUNDING. The current OBPA can support reprogramming on all late model General Motor's vehicles except: ^ Premium V-8's ^ 1996 Diesel Truck ^ Cadillac Catera Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 736513 > Mar > 97 > PROM - Reprogram Using Off Board Program Adapter > Page 6356 ^ All 1997 programmable vehicles (requires use of the Tech 2) A modification to the OBPA is being offered by Kent-Moore to support these additional vehicles and to allow reprogramming using the Tech 2. The revisions to the OBPA for the Tech 2 is very important as the Tech 2 is the only tool used for service programming for 1997 and future vehicles. To have the modifications performed, contact Kent-Moore at (800) 345-2233. The revisions (part number J 41207 REV-C) are free of charge for GM dealerships/retailers. A dealership/retailer can purchase the OBPA by contacting Kent-Moore (part number J 41207-C). Support on how to use the OBPA is provided by the Techline Customer Support Center (TCSC) at (800) 828-6860 (English) or (800) 503-3222 (French). If you need to purchase an OBPA and/or cable, contact Kent-Moore at (800) 345-2233. The OBPA retails for $695.00 (includes all revisions 1-4) under part number J 41207-C. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6368 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6369 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6375 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6376 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6387 Pressure Regulating Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6388 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations LH Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 6395 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 Torque Converter Clutch Solenoid: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Valve body cover. 2. Wiring harness from case electrical connector and leads from pressure switch. 3. Torque converter clutch solenoid bolt to auxiliary valve body. 4. 3rd clutch pressure switch. 5. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. Tighten Tighten to 12 N.m (124 lb. in.). 2. 3rd clutch pressure switch. Tighten Tighten to 12 N.m (124 lb. in.). 3. Torque converter clutch solenoid bolt to auxiliary valve body. Install new "O" ring. Tighten Tighten to 12 N.m (124 lb. in.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6400 Torque Converter Clutch Solenoid: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6401 1. Install the solenoid and O-ring or O-rings. 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6412 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6413 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6419 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6420 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6421 Pressure Regulating Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6422 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations LH Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 6429 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 Torque Converter Clutch Solenoid: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Valve body cover. 2. Wiring harness from case electrical connector and leads from pressure switch. 3. Torque converter clutch solenoid bolt to auxiliary valve body. 4. 3rd clutch pressure switch. 5. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. Tighten Tighten to 12 N.m (124 lb. in.). 2. 3rd clutch pressure switch. Tighten Tighten to 12 N.m (124 lb. in.). 3. Torque converter clutch solenoid bolt to auxiliary valve body. Install new "O" ring. Tighten Tighten to 12 N.m (124 lb. in.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6434 Torque Converter Clutch Solenoid: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6435 1. Install the solenoid and O-ring or O-rings. 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair Accumulator: Service and Repair REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Oil pan. 3. Oil strainer and O-ring seal. 4. Reverse oil pipe brackets. 5. Intermediate servo cover and gasket. 6. Third accumulator valve and spring. 7. Intermediate servo assembly. INSTALL OR CONNECT 1. Intermediate servo assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 6439 2. Third accumulator valve and spring. 3. Servo cover with a new gasket. 4. Reverse oil pipe brackets. 5. Oil strainer with a new seal. 6. Oil pan. 7. Lower vehicle. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 6448 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 6454 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 3T40 Band Apply Servo: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Oil pan. 3. Oil strainer and O-ring seal. 4. Reverse oil pipe brackets. 5. Intermediate servo cover and gasket. 6. Third accumulator valve and spring. 7. Intermediate servo assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 3T40 > Page 6457 INSTALL OR CONNECT 1. Intermediate servo assembly. 2. Third accumulator valve and spring. 3. Servo cover with a new gasket. 4. Reverse oil pipe brackets. 5. Oil strainer with a new seal. 6. Oil pan. 7. Lower vehicle. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 3T40 > Page 6458 Band Apply Servo: Service and Repair 4T40-E LO/Reverse Servo Assembly REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise and support the vehicle. 3. Servo cover bolts and cover. 4. Snap ring, piston assembly, sealing ring, and servo spring. - For disassembly of the servo piston assembly, refer to Overhaul Procedures. INSTALL OR CONNECT 1. Servo spring, sealing ring, piston assembly, snap ring, cover assembly and bolts. Tighten Servo cover bolts on 4T40E transaxle to 12 N.m (9 lb. ft.). 2. Lower vehicle. 3. Negative battery cable. Intermediate / 4TH Servo Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 3T40 > Page 6459 REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise and support the vehicle. 3. Servo cover bolts and cover. 4. Snap ring, piston assembly, sealing ring, and servo spring. - For disassembly of the servo piston assembly, refer to Overhaul Procedures. INSTALL OR CONNECT 1. Servo spring, sealing ring, piston assembly, snap ring, cover assembly and bolts. Tighten Servo cover bolts on transaxle to 12 N.m (16 lb. ft.). 2. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 3T40 > Page 6460 3. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 Case: Service and Repair 3T40 Valve Body Cover and Oil Pan Bolts When service requires the removal of the valve body cover or oil pan, the washer on the retaining bolts must be inspected to determine if they can be reused. A new bolt and washer assembly should be installed if the washer is inverted. Valve Body Cover ^ Tool Required: J 28467-360 Engine Support Fixture REMOVE OR DISCONNECT 1. Negative battery cable. 2. Transaxle bracket, refer to "Transaxle Support Assembly." 3. Valve body cover and gasket, refer to the image. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 > Page 6468 Inspect - Determine if the washer is inverted on bolts, refer to the image. 3T40 Important Use adhesive/sealant compound GM P/N 12345282 or equivalent to reduce the potential for oil leaks on bolts, refer to the image. INSTALL OR CONNECT 1. Valve body cover and gasket, refer to the 1st image in this article. Tighten Bolts to 24 N.m (18 lb. ft). 2. Transaxle mount bracket, refer to "Transaxle Support Assembly." 3. Negative battery cable. Case Cover Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 > Page 6469 ^ Tool Required: J 28467-360 Engine Support Fixture REMOVE OR DISCONNECT 1. Negative battery cable. 2. Transaxle bracket, refer to "Transaxle Support Assembly." 3. Valve body cover, refer to "Valve Body Cover." 4. TCC wires from case connector. 5. Control valve and oil pump assembly from case cover. Refer to HYDRA-MATIC for appropriate bolts to remove. Important Do not lose check balls. 6. Oil pump drive shaft. 7. Spacer plate and gaskets. 8. Case cover. - Install two 12 x 1.95 x 14 bolts in dowel pin holes and tighten equally to pull case cover loose. Important When disassembling a Hydra-Matic , inspect the drive link assembly for wear. Refer to "Drive Link Assembly." INSTALL OR CONNECT 1. Case cover. Tighten bolts to 24 N.m (18 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 > Page 6470 2. Check balls into case cover, refer to the image. 3. Spacer plate and gaskets. 4. Pump drive shaft. 5. Check ball into control valve assembly. 6. Auxiliary valve body and control valve assembly onto transaxle. 7. TCC wire to case electrical connector. 8. Valve body cover, refer to "Valve Body Cover." 9. Transaxle mount bracket, refer to "Transaxle Support Assembly." 10. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 > Page 6471 Case: Service and Repair 4T40-E Case Side Cover and Oil Pan Bolts 4T40E The self tapping bolts should be replaced with the appropriate standard service fasteners if the valve body cover of oil pan bolts are removed. Case Side Cover Oil Fill And Vent Cap - 4T40E Transaxle ^ Tools Required: J 28467-360 Engine Support Fixture - J 24319-B Steering Linkage Puller - J 38892 Ball Joint Separator REMOVE OR DISCONNECT 1. Negative battery cable. 2. Install engine support fixture, J 28467-360. 3. Air cleaner assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Service and Repair > 3T40 > Page 6472 4. Upper transaxle support assembly bolts. 5. Upper case side cover bolts. 6. Raise and support the vehicle. 7. Left wheel and tire assembly. 8. Left splash shield. 9. Transaxle mount pipe expansion bolt. 10. Transaxle mount to body bolts. 11. Lower transaxle support assembly bolts. 12. Transaxle mount and support assembly. 13. Left outer tie rod from steering knuckle assembly using J 24319-B. 14. Left ball joint from steering knuckle assembly using J 38892. 15. Brake caliper from steering knuckle assembly and support with line attached. 16. Drive axle from transaxle and support. 17. Front suspension support brace. 18. Oil cooler lines from transaxle. 19. Clips attaching wire harness to body. 20. Remove left suspension support bolts and loosen right bolts enough to remove case side cover. 21. Lower vehicle. 22. Lower transaxle with engine support fixture enough to remove case side cover. 23. Raise and support the vehicle. 24. Case side cover bolts. 25. Case side cover and gasket. Clean - Case and side cover gasket surfaces. INSTALL OR CONNECT 1. Install seal protector into side cover to prevent the seal from rolling. 2. Case side cover and gasket. 3. Case side cover lower bolts. Tighten Case side cover bolts in a general star pattern to 28 N.m (21 lb. ft.). 4. Loosely install transaxle support assembly with lower bolts. 5. Lower vehicle. 6. Raise transaxle with engine support fixture. 7. Case side cover upper bolts. Tighten Case side cover bolts in a general star pattern to 28 N.m (21 lb. ft.). 8. Upper transaxle support assembly bolts, refer to "Transaxle Mount." 9. Raise and support the vehicle. 10. Lower transaxle support assembly bolts, refer to "Transaxle Mount." 11. Transaxle mount. 12. Transaxle mount to body bolts, refer to "Transaxle Mount." 13. Attach wire harness to body. 14. Oil cooler lines to transaxle, refer to "Transaxle Oil Cooler Pipes." 15. Suspension support bolts. 16. Front suspension support brace. 17. Drive axle to transaxle. 18. Left ball joint to steering knuckle assembly. 19. Left outer tie rod to steering knuckle assembly, refer to Steering and Suspension. 20. Brake caliper to steering knuckle assembly, refer to Brakes and Traction Control. 21. Left splash shield. 22. Left wheel and tire assembly, refer to Steering and Suspension. 23. Lower vehicle. 24. Air cleaner assembly. 25. Remove engine support fixture. 26. Negative battery cable. 27. Apply brakes, start engine and shift transaxle from reverse to drive. 28. Transaxle mount pipe expansion bolt, refer to "Transaxle Mount." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6481 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6491 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6505 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6506 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak Clutch: Customer Interest A/T - Delay Engagement into Drive After Cold Soak File In Section: 7 - Transmission Bulletin No.: 67-71-60 Date: February, 1997 Subject: Delay Engagement into Drive After Cold Soak (Replace with Revised Forward Clutch Housing Assembly Complete) Models: 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1997 Oldsmobile Cutlass 1995-97 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and with 2.2L, 2.3L, 2.4L, 3.1L Engine (VINs 4, D, T, M - RPOs LN2, LD2, LD9, L82) Condition Some owners of the above models may experience an initial delay when shifting into drive after the vehicle has gone through an overnight cold soak usually at -12° C (10° F) ambient temperature or colder. This condition will not repeat until the vehicle has gone through another overnight cold soak. During the initial delay, an increase to engine RPM could cause the engagement into forward gear to be harsh. (See Figure 1) Cause Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak > Page 6511 This condition may be due to fluid draining from the forward clutch housing assembly after the vehicle's engine has been shut off. If this draining is followed by a cold soak as described under "Condition," a delay may occur to refill the forward clutch housing assembly. This delay is due to the resistance exhibited by the control orifice in the inner seal and sleeve assembly, and the amount of oil volume required to refill the forward clutch housing assembly. (See Figure 2) Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak > Page 6512 To repair this condition a revised forward clutch housing assembly complete, (including fiber and steel plates) must be installed with a revised assembly. The revision to this assembly is a new piston assembly (607) and inner seal and sleeve assembly (608). The new piston assembly has additional rubber material molded to it. The inner seal and sleeve assembly has a molded plastic insert. These revisions help reduce the volume of oil required to allow the forward clutch assembly to apply. The forward clutch housing assembly must be replaced as a complete assembly. (See Figure 3) Service Information Road test the vehicle following an overnight cold soak as described under "Condition." Verify the vehicle has a delay during the initial shift into drive. Replace the complete forward clutch housing assembly with the one supplied in service kit (P/N 24210576). Refer to the Unit Repair Section of the Service Manual for the proper procedure. A new service kit (gasket kit-trans with seals P/N 24210577) has been released which may be useful in obtaining the additional gaskets and seals that may be needed in the servicing of a lower mileage vehicle. For transaxles which require a complete reconditioning, the overhaul complete service kit should be ordered. Refer to parts catalog for the complete overhaul part number. Parts Information Part Number Description 24210576 Forward Clutch Housing Complete 24210577 Gasket Kit-Trans with Seals Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak > Page 6513 Labor Operation Description Labor Time K7221 Forward Clutch Use published R & R or Replace labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6519 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6520 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 03-07-30-006 > Mar > 03 > A/T - 4T40-E/4T45-T Engineering Changes Clutch: All Technical Service Bulletins A/T - 4T40-E/4T45-T Engineering Changes File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-006 Date: March, 2003 INFORMATION Subject: MN4 (4T40-E) MN5 (4T45-E) Engineering Changes Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1997 Oldsmobile Achieva 1997-1999 Oldsmobile Cutlass 1998-2002 Oldsmobile Intrigue 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1997-2003 Pontiac Grand Am with 4T40-E (MN4) or 4T45-E (MN5) Automatic Transmission Engineering changes have been incorporated into the MN4 and MN5 Reverse Clutch Housing and related parts beginning with transmission assemblies produced on December 4, 2002, Julian Date 02 338. Refer to the following list for the affected parts and a description of how each changed: The new Reverse Clutch Center Seal has a larger feed orifice. ^ The new Reverse Clutch Snap Ring is thicker and stiffer. ^ The new Reverse Housing Snap Ring Grove is wider to accommodate the thicker snap ring. Elimination of the Backing Plate Selectives. The new clutch assembly is built with only the thickest of the three previous selective backing plates. The new Reverse Wave Plate is stiffer. Notice: To maintain proper operating calibration of the transmission, determine which Reverse Clutch Housing, Center Seat, Snap Ring, Backing Plate and Wave Plate to use according to the Julian date on which the transmission was assembled. Failure to use these parts as instructed will cause improper function, shift feel, and possible transmission distress. The affected service kits include an instruction sheet that details the difference between the 1st and 2nd design center seals, and how to determine which to use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak Clutch: All Technical Service Bulletins A/T - Delay Engagement into Drive After Cold Soak File In Section: 7 - Transmission Bulletin No.: 67-71-60 Date: February, 1997 Subject: Delay Engagement into Drive After Cold Soak (Replace with Revised Forward Clutch Housing Assembly Complete) Models: 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1997 Oldsmobile Cutlass 1995-97 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and with 2.2L, 2.3L, 2.4L, 3.1L Engine (VINs 4, D, T, M - RPOs LN2, LD2, LD9, L82) Condition Some owners of the above models may experience an initial delay when shifting into drive after the vehicle has gone through an overnight cold soak usually at -12° C (10° F) ambient temperature or colder. This condition will not repeat until the vehicle has gone through another overnight cold soak. During the initial delay, an increase to engine RPM could cause the engagement into forward gear to be harsh. (See Figure 1) Cause Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak > Page 6529 This condition may be due to fluid draining from the forward clutch housing assembly after the vehicle's engine has been shut off. If this draining is followed by a cold soak as described under "Condition," a delay may occur to refill the forward clutch housing assembly. This delay is due to the resistance exhibited by the control orifice in the inner seal and sleeve assembly, and the amount of oil volume required to refill the forward clutch housing assembly. (See Figure 2) Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak > Page 6530 To repair this condition a revised forward clutch housing assembly complete, (including fiber and steel plates) must be installed with a revised assembly. The revision to this assembly is a new piston assembly (607) and inner seal and sleeve assembly (608). The new piston assembly has additional rubber material molded to it. The inner seal and sleeve assembly has a molded plastic insert. These revisions help reduce the volume of oil required to allow the forward clutch assembly to apply. The forward clutch housing assembly must be replaced as a complete assembly. (See Figure 3) Service Information Road test the vehicle following an overnight cold soak as described under "Condition." Verify the vehicle has a delay during the initial shift into drive. Replace the complete forward clutch housing assembly with the one supplied in service kit (P/N 24210576). Refer to the Unit Repair Section of the Service Manual for the proper procedure. A new service kit (gasket kit-trans with seals P/N 24210577) has been released which may be useful in obtaining the additional gaskets and seals that may be needed in the servicing of a lower mileage vehicle. For transaxles which require a complete reconditioning, the overhaul complete service kit should be ordered. Refer to parts catalog for the complete overhaul part number. Parts Information Part Number Description 24210576 Forward Clutch Housing Complete 24210577 Gasket Kit-Trans with Seals Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 677160 > Feb > 97 > A/T - Delay Engagement into Drive After Cold Soak > Page 6531 Labor Operation Description Labor Time K7221 Forward Clutch Use published R & R or Replace labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 03-07-30-006 > Mar > 03 > A/T - 4T40-E/4T45-T Engineering Changes Clutch: All Technical Service Bulletins A/T - 4T40-E/4T45-T Engineering Changes File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-006 Date: March, 2003 INFORMATION Subject: MN4 (4T40-E) MN5 (4T45-E) Engineering Changes Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1997 Oldsmobile Achieva 1997-1999 Oldsmobile Cutlass 1998-2002 Oldsmobile Intrigue 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1997-2003 Pontiac Grand Am with 4T40-E (MN4) or 4T45-E (MN5) Automatic Transmission Engineering changes have been incorporated into the MN4 and MN5 Reverse Clutch Housing and related parts beginning with transmission assemblies produced on December 4, 2002, Julian Date 02 338. Refer to the following list for the affected parts and a description of how each changed: The new Reverse Clutch Center Seal has a larger feed orifice. ^ The new Reverse Clutch Snap Ring is thicker and stiffer. ^ The new Reverse Housing Snap Ring Grove is wider to accommodate the thicker snap ring. Elimination of the Backing Plate Selectives. The new clutch assembly is built with only the thickest of the three previous selective backing plates. The new Reverse Wave Plate is stiffer. Notice: To maintain proper operating calibration of the transmission, determine which Reverse Clutch Housing, Center Seat, Snap Ring, Backing Plate and Wave Plate to use according to the Julian date on which the transmission was assembled. Failure to use these parts as instructed will cause improper function, shift feel, and possible transmission distress. The affected service kits include an instruction sheet that details the difference between the 1st and 2nd design center seals, and how to determine which to use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > A/T - Revised Final Drive Pinion End Play Check Differential: Technical Service Bulletins A/T - Revised Final Drive Pinion End Play Check File In Section: 7 - Transmission Bulletin No.: 77-71-79A Date: February, 1998 SERVICE MANUAL UPDATE Subject: Section 7-Transmission/Transaxle - Transfer Case Unit Repair Manual (TURM) - 4T40-E Final Drive Pinion End Play Check Specification Models: 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Cutlass 1997-98 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and 2.2L, 2.4L or 3.1L Engine (VINs 4, T, M RPOs LN2, LD9, L82) This bulletin is being revised to correct 1998 service manual page number. Please discard Corporate Bulletin Number 77-71-79 (Section 7 - Transmission). This bulletin contains the 1997 and 1998 TURM manual with revised art work for the final drive pinion end play check procedure. Replace these pages in your 1997 and 1998 TURM manual: 1997 - revised page is: 7A2B-57 1998 - revised page is: 7-754 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > A/T - Revised Final Drive Pinion End Play Check > Page 6541 4T40-E AUTOMATIC TRANSAXLE UNIT REPAIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > A/T - Revised Final Drive Pinion End Play Check > Page 6542 AUTOMATIC TRANSAXLE 4T40-E Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair Automatic Transmission Dipstick - Dipstick Tube: Service and Repair REMOVE OR DISCONNECT 1. Oil level indicator and nut or bolt retaining tube to mounting bracket. 2. Raise and support the vehicle. 3. Place drain pan under transaxle. 4. Loosen filler tube from transaxle. 5. Filler tube seal. 6. Lower vehicle. 7. Pull tube out of vehicle from the top. INSTALL OR CONNECT 1. Filler tube. 2. Raise and support the vehicle. 3. Filler tube seal into transaxle. - Lubricate with DEXRON III. 4. Filler tube into transaxle. 5. Lower vehicle. 6. Fastener retaining tube to mounting bracket, refer to the image. 7. Oil level indicator. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drive Chain, A/T > Component Information > Service and Repair Drive Chain: Service and Repair REMOVE OR DISCONNECT Valve body cover. Inspect 1. Midway between the sprockets and at right angles to the drive link, push the slack strand (bottom strand) of the drive link until all slack is removed and mark with crayon on the bottom side of the drive link. 2. Push up in the same manner and put a second mark on the case, making sure that both marks are made from the point on the drive link. Measure - The distance between the two marks. If the distance exceeds 22.2 mm (7/8 in.), replace the drive link. - Make sure the three machined surfaces as indicated are flush with the machined surface of the case, if not when drive link measurement will be inaccurate. INSTALL OR CONNECT Case cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6553 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6554 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6555 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6556 Fluid - A/T: Technical Service Bulletins A/T - Fluid Level Checking And Fill Procedure Revised File In Section: 7 - Transmission Bulletin No.: 63-71-06 Date: March, 1997 SERVICE MANUAL UPDATE Subject: Section 7A - Revised 4T40E Fluid Level Checking and Fill Procedure Models: 1997 Chevrolet Cavalier, Malibu 1997 Oldsmobile Cutlass 1997 Pontiac Sunfire This bulletin is being issued to revise the 4T40E fluid level checking and fill procedure in Section 7A of the Service Manual. The following procedure should be used for the above listed vehicles. 4T40E Fluid Level Checking and Fill Procedure The fluid level screw is intended to be used for diagnosing a transaxle fluid leak or resetting the transaxle fluid level after service that involves a loss of fluid. Inspect The fluid level should be checked when the transaxle is near 40° C (104° F). A vehicle at room temperature can be brought to 40° C (104° F) by performing the following procedure. Caution: Removal of the fluid level screw when transaxle fluid is hot may cause injury. Use care to avoid contact with the fluid and to avoid transaxle fluid splashing on to the exhaust pipe. The engine must be running when the transaxle fluid level screw is removed, or excessive fluid loss will occur. Transaxle fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fluid level screw. Have a container ready to capture any lost fluid. DO NOT TURN THE ENGINE OFF WITH THE FLUID LEVEL SCREW REMOVED AS YOU CAN BE INJURED BY HOT TRANSAXLE FLUID BEING EXPELLED OUT OF THE FLUID CHECK HOLE. 1. Let vehicle idle for three to five minutes with accessories off. 2. Apply brake. 3. Move shift lever through all gear ranges, pausing three seconds in each range. 4. Place shift lever in Park. Important: Vehicle must be kept level on the hoist. 5. Raise vehicle on hoist. Refer to "General Information". 6. Place oil container under fluid level screw. 7. Remove the fluid level screw with engine running at idle. 8. Fluid level should be at the bottom of fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to Adding Transaxle Fluid. 9. Install fluid level screw. Tighten Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 6557 Tighten 12 N.m (106 lb in.). 10. Lower vehicle. 11. Shut off engine. Adding Transaxle Fluid With the engine running, add fluid (DEXRON(R)-III) at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole. 1. Install fluid level screw. Tighten Tighten 12 N.m (106 lb in.). 2. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC 3T40 Bottom Pan Removal ........................................................................................... ...................................................................................... 3.8 liters (4.0 qts) Complete Overhaul .......... .............................................................................................................................................................. ............ 6.6 liters (7.0 qts) Dry ............................................................................................................. ................................................................................................ 8.5 liters (9.0 qts) AUTOMATIC 4T40-E Bottom Pan Removal ........................................................................................ ......................................................................................... 6.5 liters (6.9 qts) Complete Overhaul ....... .............................................................................................................................................................. ............... 9.0 liters (9.5 qts) Dry .......................................................................................................... ............................................................................................... 12.2 liters (12.9 qts) Measurements are approximate. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 6560 Fluid - A/T: Fluid Type Specifications DEXRON-III Automatic Transmission Fluid (or equivalent). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information Fluid - A/T: Testing and Inspection Transaxle Oil Information Checking Oil Level Oil Fill And Vent Cap - 4T40E Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 6563 Checking oil level, color and condition at regular intervals will provide early diagnosis information about the transaxle. This information may then be used to correct a condition that, if not detected early, could result in major transaxle repairs. When adding or changing oil, use only DEXRON III. Important When new, automatic transmission oil is red in color. The red dye is to distinguish it from engine oil or anti-freeze. The red dye is not an indicator of oil quality and is not permanent. As the vehicle is driven the transmission oil will begin to look darker in color. The color may eventually appear light brown. A dark brown color with a burnt odor may indicate oil deterioration and signal a need for a transaxle oil change. NOTICE: Do not overfill. Overfilling will cause foaming, loss of oil and possible~damage to the transaxle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 6564 Fluid - A/T: Testing and Inspection Transaxle Oil Level Checking Procedure Checking Oil Level Oil Fill And Vent Cap - 4T40E Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 6565 This procedure has been updated by TSB # 63-71-06 dated March 1997. Start engine and drive vehicle until the transaxle reaches operating temperature of 82-130°C (180-200°F). This temperature is reached after about 24 km (15 miles) of driving. NOTICE: Temperature will greatly affect transmission oil level. If the vehicle is not at normal operating temperature and the proper checking procedures are not followed, the result could be a false reading of the oil level indicator and an incorrect adjustment of the oil level. Inaccurate oil level readings will result if the oil is checked immediately after the vehicle has been operated under certain conditions: In high ambient temperature above 32°C (90°F). - At sustained high speeds. - In heavy city traffic during hot weather. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Transaxle Oil Information > Page 6566 - As a towing vehicle. - In commercial service (taxi or police use). If the vehicle has been operated under these conditions, shut the engine off and allow the vehicle to cool for thirty minutes. Then restart the vehicle and continue from step two. The fluid level screw is intended to be used for diagnosing a transaxle fluid leak or resetting the transaxle fluid level after service that involves a loss of fluid. Inspect The fluid level should be checked when the transaxle is near Room temperature or at 40°C (104°F). CAUTION: Removal of the fluid level screw when the transaxle fluid is hot may cause injury. Use care to avoid contact of transaxle fluid to exhaust pipe. The engine must be running when the transaxle fluid level screw is removed, or excessive fluid loss will occur. Since the actual fluid level is unknown, stand clear when removing the fluid level screw. Have a container ready to capture any lost fluid. WARNING: Do not turn the engine off with the fluid level screw removed as you can be injured by hot transaxle fluid being expelled out of the fluid check hole. 1. Let vehicle idle for three to five minutes with accessories off. 2. Apply brake 3. Move shift lever through all gear ranges, pausing three seconds in each range. 4. Place shift lever in Park. Important: Vehicle must be kept level on the hoist. 5. Raise vehicle on hoist. 6. Place oil container under fluid level screw. 7. Remove the fluid with the engine running at idle. 8. Fluid level should be at the bottom of the fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to ADDING TRANSAXLE FLUID. 9. Install fluid level screw. Tighten 12 N.m (106 lb in) 10. Lower vehicle. 11. Shut off engine. Adding Transaxle Fluid: With the engine running, add fluid at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole. 1. Install fluid level screw. Tighten 12 N.m (106 lb in) 2. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle Fluid - A/T: Service and Repair 3T40 Automatic Transaxle Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise the vehicle. 2. Place a drain pan under transmission oil pan. 3. Remove the oil pan bolts from the front and the sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. NOTICE: Pry the oil pan down carfully in order to prevent damage to the transmission case or the oil pan sealing surfaces. 5. Lightly tap the oil pan with rubber mallet or pry in order to allow oil to drain. 6. Inspect oil color. 7. Remove the remaining oil pan bolts. 8. Remove the oil pan. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6569 9. Remove the oil pan gasket. 10. Remove the oil filter. 11. Remove the oil filter O-ring seal. 12. Inspect the O-ring seal. The O-ring seal may be stuck in the case. 13. Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket surfaces with solvent, and allow to air dry. Installation Procedure Tools Required J 36850 Transjel Transmission Assembly Lubricant Notice: Use J 36850 or equivalent during assembly in order to retain checkballs or to lubricate components. Lubricants other than the recommended assembly lube changes the transmission fluid characteristics and causes undesirable shift conditions or filter clogging. 1. Coat seal with a small amount of J 36850, or equivalent. 2. Install a new seal into the case. 3. Install a new filter into the case. 4. Install a new oil pan gasket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6570 5. Install the oil pan. 6. Install the oil pan bolts. Tighten Tighten the bolts to 10 Nm (89 lb in). 7. Inspect the oil pan bolts and the washers. 8. Use adhesive and sealant compound GM P/N 12345382, or equivalent. 9. Lower the vehicle. 10. Fill transmission to proper level with DEXRON III oil 11. Adjust cold oil level reading for the initial fill. Do not overfill. 12. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6571 Fluid - A/T: Service and Repair 4T40-E Automatic Transaxle 4T40E REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Place drain pan under transaxle oil pan. 3. Oil pan bolts from the front and sides only. 4. Loosen rear oil pan bolts approximately 4 turns. NOTICE: Do not damage the transaxle case or oil pan sealing surfaces. 5. Lightly tap oil pan with rubber mallet or pry to allow oil to drain. Inspect - Inspect oil color. - Refer to "Checking Oil Color, Level and Condition." 6. Remaining oil pan bolts, oil pan and gasket. 7. Oil filter and O-ring. Inspect - O-ring may be stuck in the case. Clean - Transaxle case and oil pan gasket surfaces with solvent and air dry. All traces of old gasket material must be removed. INSTALL OR CONNECT 1. Coat seal with a small amount of TRANSJEL J 36850 or equivalent. 2. New seal into case. 3. New filter into case. 4. Oil pan and new gasket. 5. Oil pan bolts. Tighten Tighten the bottom pan bolts to 12 Nm (106 lb in). Inspect - Refer to "Valve Body Cover and Oil Pan Bolts" for inspection of bolts and washers. - Use adhesive/sealant compound GM P/N12345382 or equivalent to reduce the potential for oil leaks on indicated bolt, refer to the image. 6. Lower vehicle. 7. Fill transaxle to proper level with DEXRON III oil. Adjust - "Cold" oil level reading for initial fill. Do not overfill. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 3T40 Automatic Transaxle > Page 6572 8. Follow the "Transaxle Oil Level Checking Procedure." Inspect - Check oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 Fluid Filter - A/T: Service and Repair 3T40 3T40 REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Place drain pan under transaxle oil pan. 3. Oil pan bolts from the front and sides only. 4. Loosen rear oil pan bolts approximately 4 turns. NOTICE: Do not damage the transaxle case or oil pan sealing surfaces. 5. Lightly tap oil pan with rubber mallet or pry to allow oil to drain. Inspect - Inspect oil color. - Refer to "Checking Oil Color, Level and Condition." 6. Remaining oil pan bolts, oil pan and gasket. 7. Oil filter and O-ring. Inspect - O-ring may be stuck in the case. Clean - Transaxle case and oil pan gasket surfaces with solvent and air dry. All traces of old gasket material must be removed. INSTALL OR CONNECT 1. Coat seal with a small amount of TRANSJEL J 36850 or equivalent. 2. New seal into case. 3. New filter into case. 4. Oil pan and new gasket. 5. Oil pan bolts, refer to "Fastener Tightening Specifications. " Inspect - Refer to "Valve Body Cover and Oil Pan Bolts" for inspection of bolts and washers. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 > Page 6577 - Use adhesive/sealant compound GM P/N 12345382 or equivalent to reduce the potential for oil leaks on indicated bolt, refer to the image. 6. Lower vehicle. 7. Fill transaxle to proper level with DEXRON III oil. Adjust - "Cold" oil level reading for initial fill. Do not overfill. 8. Follow the "Transaxle Oil Level Checking Procedure." Inspect - Check oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 > Page 6578 Fluid Filter - A/T: Service and Repair 4T40-E Oil Filter and Seal REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Drain oil, refer-to "Changing Oil and Filter." 3. Oil pan attaching bolts, oil pan and gasket, refer to "Transaxle Oil pan and Gasket." 4. Oil filter assembly. 5. Filter neck seal from transaxle case using a small screwdriver and being careful not to score case during removal. The filter seal is not reusable and should be discarded. INSTALL OR CONNECT 1. New oil filter and new oil filter seal. Tap gently and evenly on the seal to prevent damage to the case bore or seal. 2. Oil pan gasket; may be reused, unless sealing ribs are damaged. If damaged, use new gasket. 3. Oil pan and attaching bolts, refer to "Transaxle Oil pan and Gasket." Tighten Pan bolts to 12 N.m (9 lb. ft.). 4. Lower vehicle. 5. Fill transaxle to proper level with DEXRON III Inspect - Oil pan gasket for leaks. Changing Oil and Filter Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 3T40 > Page 6579 4T40E REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Place drain pan under transaxle oil pan. 3. Oil pan bolts from the front and sides only. 4. Loosen rear oil pan bolts approximately 4 turns. NOTICE: Do not damage the transaxle case or oil pan sealing surfaces. 5. Lightly tap oil pan with rubber mallet or pry to allow oil to drain. Inspect - Inspect oil color. - Refer to "Checking Oil Color, Level and Condition." 6. Remaining oil pan bolts, oil pan and gasket. 7. Oil filter and O-ring. Inspect - O-ring may be stuck in the case. Clean - Transaxle case and oil pan gasket surfaces with solvent and air dry. All traces of old gasket material must be removed. INSTALL OR CONNECT 1. Coat seal with a small amount of TRANSJEL J 36850 or equivalent. 2. New seal into case. 3. New filter into case. 4. Oil pan and new gasket. 5. Oil pan bolts, refer to "Fastener Tightening Specifications. " Inspect - Refer to "Valve Body Cover and Oil Pan Bolts" for inspection of bolts and washers. - Use adhesive/sealant compound GM P/N12345382 or equivalent to reduce the potential for oil leaks on indicated bolt, refer to the image. 6. Lower vehicle. 7. Fill transaxle to proper level with DEXRON III oil. Adjust - "Cold" oil level reading for initial fill. Do not overfill. 8. Follow the "Transaxle Oil Level Checking Procedure." Inspect - Check oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6584 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6585 Fluid Line/Hose: Technical Service Bulletins Transaxle Cooler Line - Seal Installation Procedure File In Section: 7 - Transmission Bulletin No.: 87-71-67 Date: June, 1998 INFORMATION Subject: Transaxle Cooler Line Seal Installation Procedure Models: 1995-98 Chevrolet Cavalier 1997-98 Chevrolet Malibu 1997-98 Oldsmobile Cutlass 1999 Oldsmobile Alero 1995-98 Pontiac Sunfire 1999 Pontiac Grand Am with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) or 4T45-E Transaxle RPO MN5) and 2.2L, 2.4L, 3.1 L, 3.4L Engine VINs 4, T, M, E - RPOs LN2, LD91 L821 LA1) This bulletin contains information regarding the installation of cooler line seals into the case of either a 4T40-E or 4T45-E transaxle. Seal Installation Procedure (Figure 1) To prevent automatic transmission fluid from leaking from the cooler line seals (49) after installing new seals, perform the following procedure. Important: Only GM Goodwrench DEXRON(R) III automatic transmission fluid should be used as part of warranty repair of GM Powertrain automatic transmissions. Notice: Failure to lubricate the cooler line seals (49) with automatic transmission fluid DEXRON(R) III, before installing the cooler line pipes into the seals, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6586 may cause damage to the seals. 1. Lubricate the inside surface of both new cooler line seals (49) with automatic transmission fluid DEXRON(R) III. 2. Place a new cooler line seal (49) into the case bore. 3. Install the cooler line seal installer tool J 41239-1 on the transmission case (51) at the cooler line bracket bolt hole. 4. Press the new cooler line seal (49) in by tightening the seal pressing bolt on the cooler line seal installer tool J 41239-1 until the seal bottoms out in the case bore. 5. Repeat steps 2 through 4 for the second cooler line seal (49). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 Fluid Line/Hose: Service and Repair 3T40 If replacement of transaxle cooler pipes is required, use only double wrapped and brazed steel pipe meeting GM specification 123M or equivalent. Pipe should be double flared. NOTICE: Allow sufficient clearance around cooler pipes to prevent damage or wear which may cause oil loss. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 > Page 6589 Fluid Line/Hose: Service and Repair 4T40-E Transaxle Oil Cooler Lines REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Transaxle oil cooler lines from radiator. 3. Transaxle oil cooler line bracket bolt from transaxle. 4. Transaxle oil cooler lines from vehicle. INSTALL OR CONNECT 1. Transaxle oil cooler lines to transaxle, refer to the image. Tighten Transaxle cooler line bracket bolt to 8 N.m (71 lb. in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 > Page 6590 2. Transaxle oil cooler lines to radiator, refer to the image. Tighten Pipe fittings to 20 to 40 N.m (15 to 30 lb. ft). 3. Lower vehicle. Transaxle Oil Cooler Line Seals ^ Tools Required: J 41239-1 Cooler Pipe Seal Installer - J 41239-2 Cooler Pipe Seal Remover - J 6125b Slide Hammer - J 6471 Slide Hammer Adapter REMOVE OR DISCONNECT 1. Raise and support the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 > Page 6591 2. Transaxle oil cooler lines from transaxle, (1 bolt). 3. Seal removal tool J 41239-2 into cooler line seal. 4. Slide hammer J 6125b with adapter J 6471 to the seal removal tool. 5. Using slide hammer impact, remove the cooler line seals. INSTALL OR CONNECT 1. Tool J 41239-1 on transaxle case using cooler line bracket bolt. 2. New seal in the case bore. 3. Press new seals in by tightening the cooler line bracket bolt until seal bottoms out in the case bore. 4. Cooler lines into seals and transaxle case. Tighten Transaxle cooler line bracket bolt to 8 N.m (71 lb. in.). 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 3T40 > Page 6592 Oil Feed Pipes and Gaskets REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise Vehicle on hoist. 3. Remove lower oil pan. 4. Remove Filter assembly. 5. Remove 4 bolts attaching oil feed pipe assembly to transaxle. 6. Remove oil feed pipe assembly with the 8 seals. Inspect - Inspect the oil feed pipes for plugged passages, bent pipes or cracks. - Inspect the oil feed pipe seal rings. Verify the proper location of seal rings. Replace these seal rings only if they are cut,swelled or damaged. INSTALL OR CONNECT 1. Install the oil feed pipe assembly onto the transaxle. 2. Install, hand start and tighten the four oil feed pipe bolts. Tighten Torque the 4 bolts to 12 N.m (9 lb. ft.). 3. Install oil filter assembly. 4. Install lower oil pan and gasket assembly. See "Transaxle Oil Pan and Gasket." 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Pan bolts .............................................................................................................................................. ............................................... 14 N.m (124 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 3T40 Fluid Pan: Service and Repair 3T40 When service requires the removal of the valve body cover or oil pan, the washer on the retaining bolts must be inspected to determine if they can be reused. A new bolt and washer assembly should be installed if the washer is inverted. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 3T40 > Page 6598 Fluid Pan: Service and Repair 4T40-E Transaxle Oil Pan and Gasket REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Loosen pan bolts and drain oil. 3. Pan attaching bolts. 4. Pan and gasket. INSTALL OR CONNECT 1. Pan and gasket. Oil pan gasket may be re-used, unless sealing ribs are damaged. If damaged, use new gasket. 2. New pan attaching bolts. Tighten Pan bolts to 14 N.m (124 lb. in.). 3. Lower vehicle. 4. Refill transaxle to proper level with DEXRON III oil. Inspect - Oil pan gasket for leaks. Case Side Cover and Oil Pan Bolts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 3T40 > Page 6599 4T40E The self tapping bolts should be replaced with the appropriate standard service fasteners if the valve body cover of oil pan bolts are removed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pick-Up, A/T > Component Information > Service and Repair Fluid Pick-Up: Service and Repair REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise and support vehicle. 3. Bottom pan and filter. Refer to "Changing Oil and Filter." 4. Oil level control valve. Pull valve straight out, do not pry on valve or transaxle. INSTALL OR CONNECT 1. Oil level control valve into transaxle. Push straight on center of valve. 2. Oil filter and bottom pan. Refer to "Changing Oil and Filter." 3. Lower vehicle. 4. Negative battery cable. Adjust - Oil level, refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove Pressure switch assembly, (6 bolts). Important Inspect the O-rings for the pressure switch assembly for any damage. INSTALL OR CONNECT 1. Install the pressure switch assembly making sure all O-rings are in place. 2. Torque the 6 bolts holding the pressure switch assembly to 12 N.m (9 lb. ft.). 3. Install the transaxle case side cover. Refer to "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring > Page 6610 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 6611 Fluid Pump: Service and Repair REMOVE OR DISCONNECT 1. Negative battery cable. 2. TV cable from transaxle, refer to "TV Cable Replacement." 3. Valve body cover. Refer to "Transaxle Mount, Bracket, Valve Body Cover and Case Cover." 4. Bolt securing TCC solenoid to auxiliary valve body and solenoid. Remove TCC solenoid wiring connector from case connector. 5. TCC wires from pressure switches. 6. Bolt securing TV linkage and bracket assembly to valve body and TV linkage. 7. Remaining bolts securing valve body to case cover and valve body. Important Do not lose the six check balls. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 6612 - Do not remove the green bolt. 8. Green bolt and separate auxiliary valve body from valve body. 9. Check ball behind control valve assembly. Important If any service is required on the valve body and/or oil pump, refer to Valve Body Unit Repair. INSTALL OR CONNECT 1. Check valve behind control valve assembly. 2. Auxiliary valve body to valve body with green bolt. 3. Check ball in valve body. Refer to the image. 5. Valve body to case cover. 6. TV bracket and linkage. 7. TCC wires and wiring connectors. 8. TCC solenoid. 9. Valve body cover with a new gasket. Refer to "Transaxle mount, Bracket, Valve Body Cover and Case Cover." 10. TV cable to transaxle, refer to "TV Cable Replacement." 11. Negative battery cable. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 6613 - TV cable, refer to "TV Cable Adjustment." - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair Governor: Service and Repair REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Vehicle speed sensor (VSS) lead from transaxle. 3. Speed sensor housing bolts and housing. 4. Speed sensor housing O-ring. 5. Governor assembly. 6. Governor shaft screen assembly and seal. INSTALL OR CONNECT 1. Governor shaft screen assembly and seal. 2. Governor assembly. 3. Speed sensor housing O-ring. - Lubricate with DEXRON III. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Page 6617 4. Speed sensor housing and bolts. 5. VSS lead to transaxle. 6. Lower vehicle. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Hydraulic Thermo Valve, A/T > Component Information > Service and Repair Hydraulic Thermo Valve: Service and Repair ^ Tool Required J 29023 Element Height Gage REMOVE OR DISCONNECT Case cover. Inspect 1. Washers (413). 2. Element (412). 3. Element plate (411). Assemble 1. Set thermo pin height with J 29023. 2. Element plate (411). 3. Element (412). 4. Washers (413). 5. Use J 29023 to set washer height. INSTALL OR CONNECT Case cover. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The Upshift Indicator is illuminated to indicate optimum shift points for maximum fuel economy. When this light is on, shift transaxle to the next higher gear range, if conditions permit. This indicator is controlled by the IPC as commanded by the PCM via serial data. This telltale will not turn on as result of serial data loss (ignition in OFF/UNLOCK"). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Stub Axle Shaft and Right Hand Axle Oil Seal Output Shaft: Service and Repair Stub Axle Shaft and Right Hand Axle Oil Seal ^ Tools Required: J 38868 Shaft Removal Tool - J 6125 Slide Hammer - J 23129 Seal Removal Tool - J 41102 Axle Seal Installation Tool REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Drive axle assembly. 3. Snap ring from stub axle shaft Discard snap ring it is not reusable. 4. Pull lightly on the shaft and rotate it until the output shaft snap ring at the differential seats in the taper on the differential side gear. 5. Stub shaft from transaxle using Slide Hammer J 6125 and Shaft Removal tool J 38868. 6. Right hand axle seal from transaxle using seal removal tool J 23129 and slide hammer J 6125 or a screw driver. - Do not damage seal bore or sleeve assembly or fluid leaks may result. INSTALL OR CONNECT 1. New seal using J 41102. Lubricate seal lip with a light wipe of transmission oil. 2. Two new snap rings on the stub shaft. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Stub Axle Shaft and Right Hand Axle Oil Seal > Page 6631 Important Carefully guide axle shaft past lip seal. Do not allow shaft splines to contact any portion of the seal lip surface, otherwise damage to the seal will occur. 3. Stub shaft into transaxle using a mallet. 4. Drive Axle. 5. Lower vehicle. Inspect - For leaks. - Oil level, refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Stub Axle Shaft and Right Hand Axle Oil Seal > Page 6632 Output Shaft: Service and Repair Stub Axle Shaft Sleeve ^ Tools Required: J 38868 Shaft Removal Tool - J 6125 Slide Hammer - J 41228 Axle Shaft Sleeve Installation Tool REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Drive axle assembly. 3. Stub shaft assembly from transaxle. 4. Sleeve from stub shaft using puller J 38868. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Stub Axle Shaft and Right Hand Axle Oil Seal > Page 6633 Inspect - Inspect the sleeve for excessive wear, scratches or nicks that may cause a leak or damage to the seal portion. If sleeve appears damaged, it must be replaced. INSTALL OR CONNECT 1. New sleeve on stub shaft using J 41228. Sleeve installation tool must be installed on shaft such that the collat is located in the snap ring groove. 2. Two new snap rings on the stub shaft. 3. Stub shaft into transaxle assembly. 4. Drive axle assembly. 5. Lower vehicle. Inspect - For leaks. - Oil level, refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Stub Axle Shaft and Right Hand Axle Oil Seal > Page 6634 Output Shaft: Service and Repair Output Axle Shaft Sleeve ^ Tools Required: J 41227 Axle Shaft Sleeve Removal Tool - J 41228 Axle Shaft Sleeve Installation Tool REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Drive axle assembly. 3. Transaxle side cover assembly. 4. Sleeve from output shaft using puller J 41227. Inspect - Inspect the sleeve for excessive wear, scratches or nicks that may cause a leak or damage to the seal portion. If sleeve appears damaged, it must be replaced. INSTALL OR CONNECT 1. New sleeve on output shaft using J 41228. Sleeve installation tool must be installed on shaft such that the collar is located in the snap ring groove. 2. Two new snap rings on the output shaft. 3. Install seal protector into side cover to prevent the seal from rolling. 4. Transaxle side cover assembly. 5. Drive axle assembly. 6. Lower vehicle. Inspect - For leaks. - Oil level, refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > 3T40 Parking Lock Cable: Adjustments 3T40 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > 3T40 > Page 6639 Adjust 1. Place floor shift lever in "Park." 2. Train column lock cylinder to "Lock." 3. Unseat body housing lock from body housing. 4. With body housing still attached to the shift control mounting bracket, adjust outer cable conduit to obtain proper location for the white plastic housing in the ignition switch, refer to the image. NOTICE: Check the following: There must be no gap between the metal terminal stop and the protruding end of the white plastic collar, refer to the image. - The white plastic collar must either be flush or recessed approximately 1 mm (0.04 in.) within ignition park lock housing, refer to the image. 5. While holding outer cable conduit in position, seat body housing lock in body housing. 6. Repeat all the steps from "Inspection and Testing" under "Park/Lock Control Cable." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > 3T40 > Page 6640 Parking Lock Cable: Adjustments 4T40-E Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > 3T40 > Page 6641 Adjust 1. Place floor shift lever in "Park." 2. Train column lock cylinder to "Lock." 3. Unseat body housing lock from body housing. 4. With body housing still attached to the shift control mounting bracket, adjust outer cable conduit to obtain proper location for the white plastic housing in the ignition switch, refer to the image. NOTICE: Check the following: There must be no gap between the metal terminal stop and the protruding end of the white plastic collar, refer to the image. - The white plastic collar must either be flush or recessed approximately 1 mm (0.04 in.) within ignition park lock housing, refer to the image. 5. While holding outer cable conduit in position, seat body housing lock in body housing. 6. Repeat all the steps from "Inspection and Testing" under "Park/Lock Control Cable." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 6642 Parking Lock Cable: Service and Repair REMOVE OR DISCONNECT 1. Battery negative cable. 2. Remove console. Refer to Body and Frame. 3. Left sound insulator. Refer to Body and Frame. 4. Remove instrument cluster. 5. Loosen lower steering column bracket bolts. 6. Lower the steering column. 7. Place transaxle shift lever in "Park." 8. Turn ignition key to "Run" position. Important DO NOT attempt to proceed to Step 8 with key in any other position. 9. Slip a screwdriver blade into slot provided in ignition switch inhibitor, depress cable latch and pull cable from inhibitor. 10. Push cable connector lock button at the shifter base to the up position. 11. Snap cable from park lock lever pin. 12. Depress two (2) cable latches and remove from shifter base. 13. Cable clips. Important When installing a new park lock cable, keep shipping cover gage attached until instructed to detach at Step 2 below. The shipping cover gage will aid in proper positioning of cable. INSTALL OR CONNECT 1. With cable lock button in the up position and shift lever in the "Park" position, snap cable connector into shifter base. 2. With ignition key in the "Run" position, snap cable into inhibitor housing until snap lock is seated. Important DO NOT attempt to insert cable with key in any other position. - Remove shipping cover gage. 3. Turn ignition key to the "Lock" position. 4. Snap cable end onto shifter park lock lever pin. 5. Push cable connector hose forward to remove slack. 6. With no load applied to connector nose, snap cable connector lock button down. Important Before installing steering column to instrument panel, check for proper operation under "Inspection and Testing." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 6643 7. Raise and connect steering column. 8. Tighten lower steering column bracket bolts. 9. Install instrument cluster. 10. Left sound insulator. Refer to Body and Frame. 11. Console. Refer to Body and Frame. 12. Battery negative cable. INSPECTION AND TESTING Inspect 1. The terminal stop on column end of park lock cable must be touching the white collar that protrudes from the ignition switch. To inspect: a. Turn column lock cylinder to "Lock." b. Place floor shift lever into "Park." c. Verify correct position of terminal stop as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 6644 NOTICE: Check the following: There must be no gap between the metal terminal stop and the protruding end of the white plastic collar refer to the image. If there is a gap between the terminal stop and the collar, the position of the park lock cable must be adjusted. - The white plastic collar must be either flush or recessed approximately 1 mm (0.04 in.) within ignition park lock housing, refer to the image. If the white plastic collar is not in proper location, the position of the park lock cable must be adjusted. 2. There must be no more that 1.5 mm (0.06 in.) of travel of the white plastic collar. Check as follows: a. Column lock cylinder remains in "Lock." b. Floor shift lever remains in "Park." c. Gently depress the park lock button on the floor shift lever until resistance is felt. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 6645 d. Verify that the white plastic collar travels no more that 1.5 mm ( 0.06 in.) as shown in the image. The floor shift lever must not come out of "Park." 3. With column lock cylinder "On", verify proper movement of floor shift lever through all gear selections. 4. While moving floor shift lever through all drive gears, verify that column lock cylinder cannot be turned to the "Lock" position. 5. Check that the key can be removed with column lock cylinder in the "Lock" position and the floor shift lever in the "Park" position. Important There are five inspections that verify proper installation. The installation must pass all five tests. If one or more tests fail, the park lock cable requires adjustment. Refer to "Park/Lock Cable Adjustment" as required. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Grinding/Growling Noise in Park on Incline Parking Pawl: Technical Service Bulletins A/T - Grinding/Growling Noise in Park on Incline INFORMATION Bulletin No.: 99-07-30-030F Date: May 01, 2008 Subject: Grinding and/or Growling Noise in Park on Incline Models: 2009 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) with Hydra-Matic Front Wheel Drive (FWD) Automatic Transmissions Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-07-30-030E (Section 07 - Transmission/Transaxle). Service Information Owners of some vehicles equipped with Hydra-Matic front wheel drive transaxles may comment on a grinding and/or growling noise that is noticeable when standing in PARK on a hill or slope with the engine running and the parking brake not applied. Under these conditions, the weight of the vehicle puts a load on the parking pawl which can create a "ground-out" path through the drive axles, front struts, springs and spring towers. Normal engine noise can be transmitted to the passenger compartment through the "ground-out" path. Owners concerned about this condition should be advised to apply the parking brake prior to shifting into PARK. This is the recommended procedure described in the Owners Manual. Applying the parking brake first will put the load of the vehicle on the rear brakes rather than on the parking pawl. Refer the owner to the appropriate Owner Manual for additional details and instructions. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6658 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6659 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6665 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6666 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Muffler: All Technical Service Bulletins Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 6672 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 6678 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6679 Pressure Regulating Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 6680 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6689 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6695 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 83-64-16 > Jun > 98 > Battery - Weak, Discharged/Slow Starting/GEN or MIL On Positive: All Technical Service Bulletins Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6701 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6702 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6703 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transaxle Side Seals Seals and Gaskets: Service and Repair Transaxle Side Seals 3T40 ^ Tools Required: J 6125-1B Slide Hammer - J 23129 Axle Seal Remover - J 34115 Axle Seal Installer REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Tire and wheel assembly. 3. Inner splash shield. 4. Tie rod from steering knuckle. 5. Ball joint from steering knuckle. 6. Drive axle. 7. Seal using J 23129 and slide hammer J 6125-1B. - Do not damage seal bore. INSTALL OR CONNECT 1. New seal using J 34115. Lubricate seal lip with a light wipe of transmission oil. 2. Axle into transaxle case. Important Carefully guide axle shaft past lip seal. Do not allow shaft splines to contact any portion of the seal lip surface, otherwise damage to the seal will occur. 3. Ball joint to steering knuckle. 4. Tie rod to steering knuckle. 5. Seat drive axle into transaxle case. 6. Tire and wheel assembly. 7. Lower vehicle. Inspect - For leaks. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Stub Axle Shaft Sleeve ^ Tools Required: J 38868 Shaft Removal Tool - J 6125 Slide Hammer - J 41228 Axle Shaft Sleeve Installation Tool REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transaxle Side Seals > Page 6706 1. Raise and support the vehicle. 2. Drive axle assembly. 3. Stub shaft assembly from transaxle. 4. Sleeve from stub shaft using puller J 38868. Inspect - Inspect the sleeve for excessive wear, scratches or nicks that may cause a leak or damage to the seal portion. If sleeve appears damaged, it must be replaced. INSTALL OR CONNECT 1. New sleeve on stub shaft using J 41228. Sleeve installation tool must be installed on shaft such that the collat is located in the snap ring groove. 2. Two new snap rings on the stub shaft. 3. Stub shaft into transaxle assembly. 4. Drive axle assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transaxle Side Seals > Page 6707 5. Lower vehicle. Inspect - For leaks. - Oil level, refer to "Transaxle Oil Level Checking Procedure." Stub Axle Shaft and Right Hand Axle Oil Seal ^ Tools Required: J 38868 Shaft Removal Tool - J 6125 Slide Hammer - J 23129 Seal Removal Tool - J 41102 Axle Seal Installation Tool REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Drive axle assembly. 3. Snap ring from stub axle shaft Discard snap ring it is not reusable. 4. Pull lightly on the shaft and rotate it until the output shaft snap ring at the differential seats in the taper on the differential side gear. 5. Stub shaft from transaxle using Slide Hammer J 6125 and Shaft Removal tool J 38868. 6. Right hand axle seal from transaxle using seal removal tool J 23129 and slide hammer J 6125 or a screw driver. - Do not damage seal bore or sleeve assembly or fluid leaks may result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transaxle Side Seals > Page 6708 INSTALL OR CONNECT 1. New seal using J 41102. Lubricate seal lip with a light wipe of transmission oil. 2. Two new snap rings on the stub shaft. Important Carefully guide axle shaft past lip seal. Do not allow shaft splines to contact any portion of the seal lip surface, otherwise damage to the seal will occur. 3. Stub shaft into transaxle using a mallet. 4. Drive Axle. 5. Lower vehicle. Inspect - For leaks. - Oil level, refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transaxle Side Seals > Page 6709 Seals and Gaskets: Service and Repair Torque Converter Seal REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle assembly from vehicle. See "Transaxle Assembly". 3. Remove the torque convertor assembly from the transaxle. 4. Remove the turbine shaft O-ring from the end of the turbine shaft using a screw driver. INSTALL OR CONNECT 1. Assemble a new turbine shaft O-ring on the end of the turbine shaft. 2. Install the torque convertor onto the transaxle. 3. Install the transaxle into the vehicle. See "Transaxle Assembly". 4. Connect negative battery cable. Adjust - Oil level, refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transaxle Side Seals > Page 6710 Seals and Gaskets: Service and Repair Dip Stick Tube Seal REMOVE OR DISCONNECT 1. Oil level indicator and nut or bolt retaining tube to mounting bracket. 2. Raise and support the vehicle. 3. Place drain pan under transaxle. 4. Loosen filler tube from transaxle. 5. Filler tube seal. 6. Lower vehicle. 7. Pull tube out of vehicle from the top. INSTALL OR CONNECT 1. Filler tube. 2. Raise and support the vehicle. 3. Filler tube seal into transaxle. - Lubricate with DEXRON III. 4. Filler tube into transaxle. 5. Lower vehicle. 6. Fastener retaining tube to mounting bracket, refer to the image. 7. Oil level indicator. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove Pressure switch assembly, (6 bolts). Important Inspect the O-rings for the pressure switch assembly for any damage. INSTALL OR CONNECT 1. Install the pressure switch assembly making sure all O-rings are in place. 2. Torque the 6 bolts holding the pressure switch assembly to 12 N.m (9 lb. ft.). 3. Install the transaxle case side cover. Refer to "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6729 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6730 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6736 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6737 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 6749 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6750 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6751 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6752 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6755 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6756 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6757 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Transmission Shift Interlock <--> [Shift Interlock, A/T] > Shift Interlock Solenoid > Component Information > Locations LH Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Transmission Shift Interlock <--> [Shift Interlock, A/T] > Shift Interlock Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Page 6768 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Locations Center Passenger Compartment, Above Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 3T40 Shift Cable: Service and Repair 3T40 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 3T40 > Page 6777 REMOVE OR DISCONNECT 1. Negative battery cable. 2. Cable at transaxle selector lever. 3. Cable at transaxle cable bracket. 4. Center Console. Refer to Body and Frame. 5. Cable at shift control assembly. 6. Cable grommet at cowl. 7. Cable from Vehicle. INSTALL OR CONNECT 1. Cable through cowl and carpet. 2. Cable Grommet and bolts in cowl. Tighten Grommet bolts to 1.9 N.m (17 lb in.). 3. Cable at shift control assembly. 4. Center control. Refer to Body and Frame. 5. Cable at transaxle cable brackets. 6. Cable at transaxle selector lever. 7. Negative battery cable. 8. Adjust cable. Adjust 1. Place shift lever in "Neutral". - Neutral can be found by rotating the selector shaft clockwise from Park through Reverse to Neutral. 2. Place shift control assembly in "Neutral". 3. Push tab on cable adjuster to adjust cable in cable mounting bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 3T40 > Page 6778 Shift Cable: Service and Repair 4T40-E Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 3T40 > Page 6779 REMOVE OR DISCONNECT 1. Negative battery cable. 2. Cable at transaxle selector lever. 3. Cable at transaxle cable bracket. 4. Center Console. Refer to Body and Frame. 5. Cable at shift control assembly. 6. Cable grommet at cowl. 7. Cable from Vehicle. INSTALL OR CONNECT 1. Cable through cowl and carpet. 2. Cable Grommet and bolts in cowl. Tighten Grommet bolts to 1.9 N.m (17 lb in.). 3. Cable at shift control assembly. 4. Center control. Refer to Body and Frame. 5. Cable at transaxle cable brackets. 6. Cable at transaxle selector lever. 7. Negative battery cable. 8. Adjust cable. Adjust 1. Place shift lever in "Neutral". - Neutral can be found by rotating the selector shaft clockwise from Park through Reverse to Neutral. 2. Place shift control assembly in "Neutral". 3. Push tab on cable adjuster to adjust cable in cable mounting bracket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6788 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6789 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6795 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6796 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > A/T - Revised Procedure for TV Cable Adjustment Throttle Valve Cable/Linkage: Technical Service Bulletins A/T - Revised Procedure for TV Cable Adjustment File In Section: 7 - Transmission Bulletin No.: 73-71-05 Date: October, 1997 SERVICE MANUAL UPDATE Subject: Revised Procedure for 3T40 TV Cable Adjustment Models: 1995-96 Buick Century 1995-96 Chevrolet Beretta, Corsica 1995-98 Chevrolet Cavalier 1995-96 Oldsmobile Cutlass Ciera 1995-97 Pontiac Sunfire with 3T40 (MD9) This bulletin is being issued to revise the service procedure for adjusting the 3T40 TV cable in Section 7A of the Service Manual. The Service Manual incorrectly states the procedure to properly perform the adjustment. The correct procedure should read as follows Tools Required: 17 mm Socket, Torque Wrench Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > A/T - Revised Procedure for TV Cable Adjustment > Page 6801 Figures 1 and 2 1. Depress and hold the re-adjustment tab. 2. Pull the cable conduit out until the slider mechanism hits the stop. 3. Release the button. 4. Position the 17 mm socket with torque wrench onto the throttle body pulley cam assembly. 5. Rotate the torque wrench to the full wide open throttle (WOT) position and apply 7.0 - 10.0 N.m (62 - 69 in. lb). Important: Audible clicks will occur during this step. 6. Release the applied pressure on the torque wrench. 7. Remove the torque wrench and socket. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Page 6802 Throttle Valve Cable/Linkage: Adjustments Adjust 1. Depress and hold re-adjustment tab. 2. Pull cable conduit out until slider mechanism hits the stop. 3. Release button. 4. Remove floor mat. 5. Firmly depress accelerator pedal to the wide open throttle position. Inspect - Check that cable moves freely. The cable may appear to function properly with the engine stopped and cold. Recheck after the engine is hot. - Road test vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Page 6803 Throttle Valve Cable/Linkage: Service and Repair REMOVE OR DISCONNECT NOTICE: Observe TV cable routing when removing cable. Duplicate cable routing when installing. 1. TV cable end from accelerator control lever assembly slot. 2. TV cable conduit end from bracket by compressing locking tangs. 3. TV cable routine clips or straps. 4. Bolt securing TV cable to transaxle. - Pull up on cable cover at transaxle until cable is visible. 5. Cable from transaxle link. 6. Transaxle case seal. INSTALL OR CONNECT 1. New seal into transaxle case hole. 2. Transaxle end of cable to TV link and secure to transaxle case with bolt and washer assembly. Tighten Bolts to specifications. Refer to "Fastener Tightening Specifications." 3. TV cable routing clips or straps. 4. TV cable conduit end to bracket. 5. TV cable into accelerator control lever assembly slot. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Page 6804 Important Avoid damaging or kinking wire cable. Inspect - Pull on upper end of cable. It should travel a short distance with light resistance caused by the small return spring on the TV lever. When releasing the upper end of the TV cable it should return to the zero TV position. Adjust - TV cable. Refer to "TV Cable Adjustment." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 6809 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flywheel/Torque Converter Vibration Test Procedure - 3T40 Torque Converter: Testing and Inspection Flywheel/Torque Converter Vibration Test Procedure 3T40 1. Start engine. 2. With engine at idle speed and the transaxle in "Park" or "Neutral", observe vibration. 3. Shut off engine. REMOVE OR DISCONNECT a. Converter shield attaching bolts. b. Flywheel to torque converter attaching bolts. c. Rotate torque converter; 120° (1/3 turn). INSTALL OR CONNECT a. Torque converter to flywheel bolts. Apply adhesive/sealant compound GM P/N 12345493 or equivalent to flywheel bolts. Tighten - Bolts to 62 N.m (46 lb ft). Hand start and tighten "net slot" bolt first. Hand start and tighten the two remaining bolts. b. Transaxle converter cover bolts. Tighten Bolts to 10 N.m (18 lb ft). 4. Start engine and check for vibration. Repeat this procedure until the best possible balance is obtained by moving flywheel 120°. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flywheel/Torque Converter Vibration Test Procedure - 3T40 > Page 6812 Torque Converter: Testing and Inspection Flywheel/Torque Converter Vibration Test Procedure 4T40-E Transaxle 1. Start engine. 2. With engine at idle speed and the transaxle in "Park" or "Neutral", observe vibration. 3. Shut off engine. REMOVE OR DISCONNECT a. Converter shield attaching bolts. b. Flywheel to torque converter attaching bolts. c. Rotate torque converter; 120° (1/3 turn). INSTALL OR CONNECT a. Torque converter to flywheel bolts. Apply adhesive/sealant compound GM P/N 12345493 or equivalent to flywheel bolts. Tighten - Bolts to 62 N.m (46 lb ft). Hand start and tighten "net slot" bolt first. Hand start and tighten the two remaining bolts. b. Transaxle converter cover bolts. Tighten Bolts to 10 N.m (18 lb ft). 4. Start engine and check for vibration. Repeat this procedure until the best possible balance is obtained by moving flywheel 120°. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Flywheel to Torque Converter Bolts Torque Converter: Service and Repair Flywheel to Torque Converter Bolts REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Transaxle converter cover bolts and cover, refer to the image. 3. Mark relationship of converter to flywheel. 4. Three bolts attaching converter to flywheel. INSTALL OR CONNECT 1. Bolts attaching converter to flywheel. Tighten All bolts to 62 N.m (46 lb. ft.). Re-torque the first bolt after all three have been tightened. 2. Converter cover and attaching bolts. Tighten Bolts to 10 N.m (89 lb. in.). 3. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Flywheel to Torque Converter Bolts > Page 6815 Torque Converter: Service and Repair Torque Convertor and Turbine Shaft Seal REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle assembly from vehicle. See "Transaxle Assembly". 3. Remove the torque convertor assembly from the transaxle. 4. Remove the turbine shaft O-ring from the end of the turbine shaft using a screw driver. INSTALL OR CONNECT 1. Assemble a new turbine shaft O-ring on the end of the turbine shaft. 2. Install the torque convertor onto the transaxle. 3. Install the transaxle into the vehicle. See "Transaxle Assembly". 4. Connect negative battery cable. Adjust - Oil level, refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6820 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Specifications > Mechanical Specifications Torque Converter Clutch: Mechanical Specifications Case Cover .......................................................................................................................................... ........................................................ 24 N.m (18 lb ft) Case Side Cover .............................................. ............................................................................................................................................ 28 N.m (21 lb ft) Cooler Pipes at Case ............................................................................................................ ........................................................................ 8 N.m (71 lb in.) Cooler Pipes at Radiator .................. ............................................................................................................................................. 20 - 40 N.m (15 - 30 lb ft) Converter Shield ..................................................................................................... .................................................................................... 10 N.m (18 lb ft) Flywheel to Torque Converter ............................................................................................................................................. ....................... 62 N.m (46 lb ft) Lo/Reverse Servo Cover Bolts ......................................................... ............................................................................................................. 12 N.m (9 lb ft) Oil Check Plug ..................................................................................................................................................... ................................... 14 N.m (124 lb in.) Oil Pan To Case ................................................................ ....................................................................................................................... 14 N.m (124 lb in.) Park/Neutral Position Switch to Case .......................................................................................................................................................... 24 N.m (18 lb ft) Pipe Expansion Bolt .................................................................................................. .................................................................................. 55 N.m (41 lb ft) Shift Control Cable Grommet . .............................................................................................................................................................. ...... 2 N.m ( 17 lb in.) Shift Lever to Transaxle Nut ............................................................................. .......................................................................................... 20 N.m (15 lb ft) Speed Sensor Housing to Case ................................................................................................................................................ ................... 11 Nm (97 lb in.) Transaxle to Engine Brace ................................................................... ....................................................................................................... 43 N.m (32 lb ft) Transaxle To Engine Mount Bolts .............................................................................................................................................................. 90 N.m (66 lb ft) TV Cable to Case ..................................................................................................... .................................................................................... 9 N.m (80 lb in) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Specifications > Mechanical Specifications > Page 6825 Torque Converter Clutch: Fluid Type Specifications Bolt, Transaxle Pan .................................................................................................................................. Adhesive/Sealant Compound GM P/N 12345382 Bolt, Valve Body ...................................................................................................................................... Adhesive/Sealant Compound GM P/N 12345382 Hub, Torque Converter Pilot ............................................................................................................................................ Chassis Grease GM P/N 1051344 Cable, Shift ................................................................................................ ....................................................................... Chassis Grease GM P/N 1051344 Case Repair ......... ........................................................................................................................................................... Epoxy Adhesive GM P/N 1052533 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Specifications > Page 6826 Torque Converter Clutch: Locations LH Engine/Transaxle LH Front Of Engine/Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Specifications > Page 6827 Torque Converter Clutch: Service Precautions CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to CAUTIONS in "ON-VEHICLE SERVICE" and the SIR Component and Wiring Location view in POWERTRAIN MANAGEMENT before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs . CAUTION: Before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with "live" or "hot at all times" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the "off" or "lock" position. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for-the application. General Motors will call out those fasteners that require a replacement after removal. General Motors will-also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect 'the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. WARNING: When self-threading fasteners are removed it is important to thoroughly-clean the bolt holes to remove debris created by the thread forming process. In addition, inspect the threads for damage and repair as necessary. Self-threading fasteners may be reused if they are not damaged. However, if a fastener need to be replaced, service fasteners are available and should be used. Self threading fasteners should not be used as replacement fasteners. Service fasteners are recognizable by their color. Service fasteners interior to the transaxle are gold/yellow in color. Service fasteners exterior to the transaxle are a light grey color. Also, service fasteners are approximately 4 mm shorter than self-threading fasteners. Self-threading fasteners are a dark gray/black color. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 3T40 Torque Converter Clutch: Description and Operation 3T40 The Torque Converter Clutch (TCC) system uses controls that are internal as well as external to the transaxle. Internal control components of the TCC system include: 1. TCC Solenoid Assembly - Energizes to redirect transaxle oil to the converter clutch control valve in the auxiliary control valve assembly. 2. TCC Pulse-Width Modulated Solenoid - Acts with TCC regulator valve to control the apply and release feel of the TCC. 3. Second Gear Switch - Closes when transaxle is in second gear to complete electrical circuit of TCC solenoid to ECM. This switch also has a second set of contacts that is normally closed and opens in second gear. This is for a second gear signal circuit that is monitored by the ECM. 4. Third Gear Switch - Normally closed and will open in third gear. This is used for third gear signal circuit on torque management applications. The switch closes to complete the TCC circuit. 5. Auxiliary Valve Body - Contains the TCC control valve. The control valve determines method of oil feed to torque converter assembly in order to enable or disable clutch mechanism. 6. Shift Solenoids - Energize to redirect oil to the appropriate shift valve. The external control components of the TCC system include: 1. Brake Release Switch - To avoid stalling the engine when braking, the converter clutch is released any time the brakes are applied. 2. Electronic Control Module or Powertrain Control Module - Receives input signals and grounds TCC solenoid to apply clutch when proper operating conditions are met. 3. Throttle Position Sensor - Sends throttle position information to Electronic Control Module. 4. MAP Sensor - Sends engine vacuum (load) information to Electronic Control Module. 5. Vehicle Speed Sensor - Sends vehicle speed information to Electronic Control Module. 6. Engine Coolant Temperature Sensor - Sends engine coolant temperature information to Electronic Control Module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > 3T40 > Page 6830 Torque Converter Clutch: Description and Operation 4T40-E The Torque Converter Clutch (TCC) system uses controls that are internal as well as external to the transaxle. Internal control components of the TCC system include: 1. TCC Solenoid Assembly - Energizes to redirect transaxle oil to the converter clutch control valve in the auxiliary control valve assembly. 2. TCC Pulse-Width Modulated Solenoid - Acts with TCC regulator valve to control the apply and release feel of the TCC. 3. Second Gear Switch - Closes when transaxle is in second gear to complete electrical circuit of TCC solenoid to ECM. This switch also has a second set of contacts that is normally closed and opens in second gear. This is for a second gear signal circuit that is monitored by the ECM. 4. Third Gear Switch - Normally closed and will open in third gear. This is used for third gear signal circuit on torque management applications. The switch closes to complete the TCC circuit. 5. Auxiliary Valve Body - Contains the TCC control valve. The control valve determines method of oil feed to torque converter assembly in order to enable or disable clutch mechanism. 6. Shift Solenoids - Energize to redirect oil to the appropriate shift valve. The external control components of the TCC system include: 1. Brake Release Switch - To avoid stalling the engine when braking, the converter clutch is released any time the brakes are applied. 2. Electronic Control Module or Powertrain Control Module - Receives input signals and grounds TCC solenoid to apply clutch when proper operating conditions are met. 3. Throttle Position Sensor - Sends throttle position information to Electronic Control Module. 4. MAP Sensor - Sends engine vacuum (load) information to Electronic Control Module. 5. Vehicle Speed Sensor - Sends vehicle speed information to Electronic Control Module. 6. Engine Coolant Temperature Sensor - Sends engine coolant temperature information to Electronic Control Module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Torque Converter Clutch: Initial Inspection and Diagnostic Overview Functional Check - TCC - 3T40 Transaxle PRELIMINARY CHECKING PROCEDURE The purpose of the preliminary checking procedure is to isolate external electrical problems from internal ones. Important: You may use a DLC scanner in order to verify the electrical circuit. Remember, a complete circuit does not indicate that the solenoid will apply. Important: Do not bench test using an automotive type battery. Accidentally crossed wires will damage the internal diodes of the TCC solenoid. FUNCTIONAL CHECK PROCEDURE 1. Install a tachometer or a scan tool. 2. Operate the vehicle until you have reached the proper operating temperature. 3. Drive the vehicle at 80-88 km/h (50-55 mph) with a light throttle (road load). 4. Maintaining throttle speed, lightly touch the brake pedal. Check for the release of the TCC and a slight increase in engine speed. 5. Release the brake and slowly accelerate. Check for a reapply of the converter clutch and a slight decrease in engine speed. EXTERNAL CONTROLS 1. Connect a voltmeter between the transmission electrical connector and the ground. 2. Turn the key ON. 3. If zero or low voltage is found, refer to Powertrain Management for electrical diagnosis. 4. If 12 volts are present at the connector, diagnose TCC hydraulic system. Functional Check - 4T40-E Transaxle 1. Install a tachometer or a scan tool. 2. Operate the vehicle until you have reached the proper operating temperature. 3. Drive the vehicle at 80-88 km/h (50-55 mph) with a light throttle (road load). 4. Maintaining throttle speed, lightly touch the brake pedal. Check for the release of the TCC and a slight increase in engine speed. 5. Release the brake and slowly accelerate. Check for a reapply of the converter clutch and a slight decrease in engine speed. General Information - TCC - 3T40 Transaxle In order to properly diagnose the Torque Converter Clutch (TCC) system, perform all electrical testing first and then perform the hydraulic testing. The Torque Converter Clutch (TCC) is applied by fluid pressure, which is controlled by a solenoid valve. This solenoid valve is located inside of the automatic transmission assembly. The solenoid valve energizes or de-energizes by making or breaking an electrical circuit through the PCM and brake switch. Preliminary Checks - TCC - 3T40 Transaxle To properly diagnose the Torque Converter Clutch (TCC) system perform all electrical testing first and then the hydraulic testing. Refer to Powertrain Management for additional information. Preliminary Checks - TCC - 4T40-E Transaxle To properly diagnose the Torque Converter Clutch (TCC) system perform all electrical testing first and then the hydraulic testing. Refer to Powertrain Management for additional information. Preliminary Information - TCC - 4T40-E Transaxle In order to properly diagnose the TCC system, perform all electrical testing first. Then perform the hydraulic testing. The Torque Converter Clutch (TCC) is applied by fluid pressure, which is controlled by a solenoid valve. This solenoid valve is located inside of the valve body. The solenoid valve energizes by completing an electrical circuit through a combination of switches and sensors. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6833 Torque Converter Clutch: Diagnostic Trouble Code Tests and Associated Procedures NOTE: You will use the fluid level screw (2) for diagnosing a transmission fluid leak or for resetting the transmission fluid level after service that involves a loss of fluid. Fluid Level Diagnosis Procedure Check the fluid level when the transmission is above 4O°C (104°F). This temperature can be reached by performing the following procedure: 1. Park the vehicle on a hoist, inspection pit, or similar raised level surface. The vehicle must be level to obtain a correct fluid level measurement. 2. Place a fluid container below the fluid level screw (2). 3. Start the engine and allow the engine to idle for approximately 5 minutes, or, if possible, drive the vehicle for a few miles to warm the transmission fluid. 4. Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the Park position. 5. Remove the fluid level screw (2). Because the transmission operates correctly over a range of fluid levels, fluid may or may not drain out of the screw hole when the screw is removed. CAUTION: Do not remove the fluid level screw If the transmission fluid is hot. This may cause injury if the fluid drains from the screw hole. - If fluid drains through the screw hole, the transmission may have been overfilled. When the fluid stops draining, the fluid level is correct. Install the fluid level screw (2) and torque to the proper specification (12 N.m). - If fluid does not drain through the screw hole (2), the transmission fluid level may be low. Add fluid through the fill cap (1) hole in 0.5-liter increments, up to 1.5 liters maximum, until fluid drains through the screw hole. If fluid drains through the screw hole, the fluid level was in the correct operating range. Allow the fluid to finish draining through the screw hole and install the fluid level screw. Torque the fluid level screw to the proper specification (12 N.m). - If fluid does not drain through the screw hold after adding a total of 1.5 liters, then the transmission was either underfilled or the transmission is leaking fluid. Inspect the transmission for fluid leaks. Fix any leaks before setting the transmission fluid level. 6. When the fluid level checking procedure is completed, wipe any fluid from the transmission case with a rag or shop towel. also, check, that the fluid fill cap (1) and the vent tube are properly installed. Fluid Level Set After Service After service, set the fluid level according to the following procedure. 1. Add fluid through the fill cap hole prior to adjusting the fluid level. The amount of fluid to add should be based on the table at the end of this procedure. 2. Follow steps 1-4 of the Fluid Level Diagnosis Procedure. 3. Add additional fluid through the fill cap (1) hole in 0.5-liter (1-pint) increments until the fluid comes out through the screw hole. 4. Allow the fluid to finish draining out through the screw hole, then install the fluid level screw (2) and torque the screw to the proper specification (12 N.m). 5. When the fluid level setting procedure is completed, wipe any fluid from the transmission case with a rag or shop towel. Also, check that the fluid Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6834 fill cap (1) and the vent tube are properly installed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6835 Torque Converter Clutch: Symptom Related Diagnostic Procedures Noise - TCC Diagnosis - 3T40 You may notice a torque converter whine when the vehicle is stopped and the transmission is in Drive or Reverse. This noise will increase as you increase the engine RPM. The noise will stop when the vehicle is moving or when you apply the torque converter clutch, because both halves of the converter are turning at the same speed. Perform a stall test to make sure the noise is actually coming from the converter: 1. Place your foot on the brake. 2. Put the gear selector in Drive. NOTICE: You may damage the transmission if you depress the accelerator for more than six seconds. 3. Depress the accelerator to approximately 1200 RPM for no more than six seconds. A torque converter noise will increase under this load. Important: Do not confuse this noise with pump whine noise, which is usually noticeable in Park, Neutral, and all other gear ranges. Pump whine will vary with line pressure. Replace the torque converter under any of the following conditions: - External leaks appear in the hub weld area. - The converter hub is scored or damaged. - The converter pilot is broken, damaged, or fits poorly into the crankshaft. - You discover steel particles after flushing the cooler and the cooler lines. - The pump is damaged, or you discover steel particles in the converter. - The vehicle has TCC shudder and/or no TCC apply. Replace the torque converter only after all hydraulic and electrical diagnoses have been made. The converter clutch material may be glazed. - The converter has an imbalance which cannot be corrected. Refer to Flywheel/Torque Converter Vibration Test. See: Testing and Inspection/Component Tests and General Diagnostics/Flexplate/Torque Converter Vibration Test - 3T40 Transaxle - The converter is contaminated with engine coolant which contains antifreeze. - An internal failure occurs in the stator roller clutch. - You notice excessive end play. - Overheating produces heavy debris in the clutch. - You discover steel particles or clutch lining material in the fluid filter or on the magnet, when no internal parts in the unit are worn or damaged. This condition indicates that lining material came from the converter. Do not replace the torque converter if you discover any of the following symptoms: - The oil has an odor or the oil is discolored, even though metal or clutch facing particles are not present. - The threads in one or more of the converter bolt holds are damaged. Correct the condition with a thread insert. - Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining material in the unit and inside the fluid filter. - The vehicle has been exposed to high mileage only. An exception may exist where the lining of the torque converter clutch dampener plate has seen excess wear by vehicles operated in heavy and/or constant traffic, such as taxi, delivery, or police use. Noise - 4T40-E Transaxle Important: Do not confuse this noise with pump whine noise, which is usually noticeable in Park, Neutral, and all other gear ranges. Pump whine will vary with line pressure. You may notice a torque converter whine when the vehicle is stopped and the transaxle is in Drive or Reverse. This noise will increase as you increase the engine RPM. The noise will stop when the vehicle is moving.or when you apply the torque converter clutch, because both halves of the converter are turning at the same speed. Perform a stall test to make sure the noise is actually coming from the converter: 1. Place your foot on the brake. 2. Put the gear selector in Drive. NOTICE: You may damage the transmission if you depress the accelerator for more than six seconds. 3. Depress the accelerator to approximately 1200 RPM for no more than six seconds. A torque converter noise will increase under this load. Poor Acceleration at High Speed - TCC Diagnosis - 3T40 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6836 - If the stator is locked up at all times, performance is normal when accelerating from a stand still. Engine RPM and car speed are limited or restricted at high speeds. Visual examination of the converter may reveal a blue color from overheating. - If the converter has been removed, you can check the stator roller clutch by inserting two fingers into the splined inner race of the roller clutch and trying to turn the race in both directions. You should be able to freely turn the inner race clockwise, but you should have difficulty in moving the inner race counterclockwise or you may be unable to move the race at all. - Do not use such items as the driven sprocket support or shafts in order to turn the race. The results may be misleading. Poor Acceleration at High Speed - 4T40-E Transaxle If the stator is locked up at all times, performance is normal when accelerating from a standstill. Engine RPM and car speed are limited or restricted at high speeds.Visual examination of the converter may reveal a blue color from overheating. If the converter has been removed, you can check the stator roller clutch by inserting two fingers into the splined inner race of the roller clutch and trying to turn the race in both directions. You should be able to freely turn the inner race clockwise, but you should have difficulty in moving the inner race counterclockwise or you may be unable to move the race at all. Poor Acceleration at Low Speed - TCC Diagnosis - 3T40 If the stator is freewheeling at all times, the car tends to have poor acceleration from a standstill. At speeds above 50-55 km/h (30-35 mph), the car may act normally. For poor acceleration, you should first determine that the exhaust system is not blocked, the engine timing is correct, and the transmission is in First gear when starting out. If the engine freely accelerates to high RPM in Neutral, you can assume that the engine and the exhaust system are normal. Check for poor performance in Drive and Reverse to help determine if the stator is freewheeling at all times. Poor Acceleration at Low Speed - 4T40-E Transaxle If the stator is freewheeling at all times, the car tends to have poor acceleration from a standstill. At speeds above 50-55 km/h (30-35 mph), the car may act normally. For poor acceleration, you should first determine that the exhaust system is not blocked, and the transmission is in First gear when starting If the engine freely accelerates to high RPM in Neutral, you can assume that the engine and the exhaust system are normal. Check for poor performance in Drive and Reverse to help determine if the stator is freewheeling at all times. TCC Shudder - TCC Diagnosis - 3T40 The key to diagnosing Torque Converter Clutch (TCC) shudder is to note when it happens and under what conditions. TCC shudder which is caused by the transmission should only occur during the apply or the release of the converter clutch. Shudder should never occur after the TCC plate is fully applied. If the shudder occurs while the TCC is applying, the problem can be within the "transmission or the torque converter. Something is causing one of the following conditions to occur: - Something is not allowing the clutch to become fully engaged. - Something is not allowing the clutch to release. - The clutch is releasing and applying at the same time. One of the following conditions may be causing the problem to occur: - Leaking turbine shaft seals - A restricted release orifice - A distorted clutch or housing surface due to long converter bolts - Defective friction material on the TCC plate If shudder occurs after the TCC has applied,most of the time there is nothing wrong with the transmission. As mentioned above, the TCC is not likely to slip after the TCC has-been applied. Engine problems may go unnoticed under light throttle and load, but they become noticeable after the TCC apply when going up a hill or accelerating. This is due to the mechanical coupling between the engine and the transmission. Once TCC is applied, there is no torque converter (fluid coupling) assistance. Engine or driveline vibrations could be unnoticeable before TCC engagement. Inspect the following components in order to avoid misdiagnosis of TCC shudder. An inspection will also avoid the unnecessary disassembly of a transmission or the unnecessary replacement of a converter. - Spark plugs - Inspect for cracks, high resistance or a broken insulator. - Plug wires - Look in each end. If there is red dust (ozone) or a black substance (carbon) present, then the wires are bad. Also look for a white discoloration of the wire. This indicates arcing during hard acceleration. - Coils - Check for coil misfire. - Fuel injectors - The filter may be plugged. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6837 - Vacuum leak - The engine will not get a correct amount of fuel. The mixture may run rich or lean depending on where the leak occurs. - EGR valve - The valve may let in too much or too little-unburnable exhaust gas and could cause the engine to run rich or lean. - MAP/MAF sensor- Like a vacuum leak, the engine will not get the correct amount of fuel for proper engine operation. - Carbon on the intake valves - Carbon restricts the proper flow of air/fuel mixture into the cylinders. - Flat cam - Valves do not open enough to let the proper fuel/air mixture into the cylinders. - Oxygen sensors - This sensor may command the engine too rich or too lean for too long. - Fuel pressure - This may be too low. - Engine mounts - Vibration of the mounts can be multiplied by TCC engagement. - Axle joints - Check for vibration. - TP Sensor - The TCC apply and release depends on the TP Sensor in many engines. If the TP Sensor is out of specification, TCC may remain applied during initial engine loading. - Cylinder balance - Bad piston rings or poorly sealing valves can cause low power in a cylinder. - Fuel contamination - This causes poor engine performance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6838 Torque Converter Clutch: Component Tests and General Diagnostics Torque Converter Stator - TCC Diagnosis - 3T40 - The torque converter stator roller clutch can have two different malfunctions. - The stator assembly freewheels in both directions. - The stator assembly remains locked up at all times. Torque Converter Stator - 4T40-E Transaxle The torque converter stator roller clutch can have two different malfunctions. - The stator assembly.freewheels in both directions. - The stator assembly remains locked up at all times. When to Replace the Torque Converter - 4T40-E Transaxle Replace the torque converter under any of the following conditions: - External leaks appear in the hub weld area. - The converter hub is scored or damaged. - The converter pilot is broken, damaged, or fits poorly into the crankshaft. - You discover steel particles after flushing the cooler and the cooler lines. - The pump is damaged, or you discover steel particles in the converter. - The vehicle has TCC shudder and/or no TCC apply. Replace the torque converter only after all hydraulic and electrical diagnoses have been made. The converter clutch material may be glazed. - The converter has an imbalance which cannot be corrected. Refer to the Flexplate/Torque Converter Vibration Test Procedure. - The converter is contaminated with engine coolant which contains antifreeze. - An internal failure occurs in the stator roller clutch. - You notice excessive end play. - Overheating produces heavy debris in the clutch. - You discover steel particles or clutch lining material in the fluid filter or on the magnet, when no internal parts in the unit are worn or damaged. This condition indicates that lining material came from the converter. When You Do Not Replace the Torque Converter - 4T40-E Transaxle Do not replace the torque converter if you discover any of the following symptoms: - The oil has an odor or the oil is discolored, even though metal or clutch facing particles are not present. - The threads in one or more of the converter bolt holds are damaged. Correct the condition with a thread insert. Refer to Engine. - Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining material in the unit and inside the fluid filter. - The vehicle has been exposed to high mileage only. An exception may exist where the lining of the torque converter clutch dampener plate has seen excess wear by vehicles operated in heavy and/or constant traffic, such as taxi, delivery, or police use. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Service and Repair > Remove or Disconnect Torque Converter Clutch: Service and Repair Remove or Disconnect ^ Tools Required: J 28467-360 Engine Support Fixture - J 24319-B Steering Linkage Puller - J 38892 Ball Joint Separator - J 35944 Oil Cooler Flushing Tool REMOVE OR DISCONNECT 1. Negative battery cable. 2. Air cleaner assembly. 3. Shift linkage from transaxle. 4. Wiring connections from transaxle. 5. Install J 28467-360 engine support fixture. 6. Upper transaxle to engine bolts. 7. Raise and support the vehicle. 8. Both tire and wheel assemblies. 9. Right and left splash shields. 10. Both front ABS wheel speed sensors and harness from left side suspension support. 11. Both outer tie rods from steering knuckle assembly using J 24319-B. 12. Both ball joints from steering knuckle assembly using J 38892. 13. Front suspension support brace. 14. Engine mount strut from strut mount bracket. 15. Support suspension support assembly and remove bolts. 16. Lower suspension support assembly enough to disconnect steering coupling and both power steering fluid lines. 17. Both drive axles from transaxle and support. 18. Engine to transaxle brace, refer to "Transaxle Brace." 19. Shift cable bracket. 20. Starter, refer to Starting and Charging. 21. Transaxle converter cover. 22. Mark the flywheel to torque converter relationship for reassembly. 23. Torque converter to flywheel bolts. 24. Transaxle cooler pipes. 25. Brake hose bracket to body. 26. Transaxle mount pipe expansion bolt. 27. Transaxle mount to body bolts. 28. Lower vehicle. 29. Lower transaxle with engine support fixture enough to remove transaxle. 30. Raise and support the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Service and Repair > Remove or Disconnect > Page 6841 31. Support transaxle. 32. Transaxle to engine bolts. 33. Transaxle. Inspect - For inspection and overhaul procedures, refer to Overhaul Procedures. Clean Transaxle cooler and lines should be flushed with J 35944 or equivalent whenever the transaxle has been removed for overhaul, replacement, torque converter, oil pump, or case. See "Transaxle Cooler Flushing" for flushing Recoil cooler and lines. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Service and Repair > Remove or Disconnect > Page 6842 Torque Converter Clutch: Service and Repair Install or Connect INSTALL OR CONNECT 1. Place a thin film of chassis grease GM P/N 1051344 or equivalent on the torque converter pilot hub. Make sure to properly seat the torque converter in the oil pump. 2. Position transaxle in vehicle. 3. Lower transaxle to engine bolts. 4. Lower vehicle. 5. Raise transaxle with engine support fixture. 6. Raise and support the vehicle. 7. Transaxle mount to body bolts, refer to "Transaxle Mount." 8. Brake hose bracket to body, refer to Brakes and Traction Control. 9. Transaxle cooler pipes, refer to "Transaxle oil cooler pipes." 10. Torque converter to flywheel bolts. Tighten Hand start all bolts, then tighten to 62 N.m (46 lb ft). 11. Transaxle converter cover. Tighten Fully driven, seated, and not stripped. 12. Starter, refer to Starting and Charging. 13. Shift cable bracket. Tighten Bolt to 25 N.m (18 lb ft). - Nut to 50 N.m (37 lb ft). 14. Engine to transaxle brace, refer to "Transaxle Brace." 15. Both drive axles. 16. Raise suspension support assembly enough to connect steering coupling and both power steering fluid lines, refer to Steering and Suspension. 17. Support suspension support assembly bolts. 18. Engine mount strut to suspension support. Refer to Engine Mechanical. 19. Front suspension support brace. 20. Both ball joints to steering knuckle assembly. 21. Both outer tie rods to steering knuckle assembly, refer to Steering and Suspension. 22. Both front ABS wheel speed sensors and harness to left side suspension support. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Service and Repair > Remove or Disconnect > Page 6843 23. Right and left splash shields. 24. Both tire and wheel assemblies, refer to Steering and Suspension. 25. Lower vehicle. 26. Upper transaxle to engine bolts. 27. Remove Engine Support Fixture J 28467-360. 28. Wiring connections to transaxle. 29. Shift linkage to transaxle. 30. Air cleaner assembly. 31. Negative battery cable. 32. Transaxle oil, refer to "Transaxle Oil Level Checking Procedure." 33. Apply brakes, start engine and shift transaxle from reverse to drive. 34. Transaxle mount pipe expansion bolt, refer to "Transaxle Mount." Adjust Shift linkage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Service and Repair > Page 6844 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 Torque Converter Clutch Solenoid: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Valve body cover. 2. Wiring harness from case electrical connector and leads from pressure switch. 3. Torque converter clutch solenoid bolt to auxiliary valve body. 4. 3rd clutch pressure switch. 5. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. Tighten Tighten to 12 N.m (124 lb. in.). 2. 3rd clutch pressure switch. Tighten Tighten to 12 N.m (124 lb. in.). 3. Torque converter clutch solenoid bolt to auxiliary valve body. Install new "O" ring. Tighten Tighten to 12 N.m (124 lb. in.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6849 Torque Converter Clutch Solenoid: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 6850 1. Install the solenoid and O-ring or O-rings. 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6855 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6856 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6857 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6858 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6859 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6860 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6861 Transmission Cooler: Technical Service Bulletins A/T - Cooler Flush Adapter Tools File In Section: 7 - Transmission Bulletin No.: 77-71-68 Date: October, 1997 INFORMATION Subject: Cooler Flush Adapter Tools for HYDRA-MATIC 4T40-E Transaxle and 4L60-E Transmission Models: 1995-98 Chevrolet Cavalier 1997-98 Chevrolet Malibu 1997-98 Oldsmobile Cutlass 1995-98 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and with 2.2L, 2.4L or 3.1 L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) 1998 Chevrolet Camaro 1998 Oldsmobile Bravada 1998 Pontiac Firebird 1996-98 Chevrolet and GMC C/K, G Models 1998 Chevrolet and GMC M/L, S/T Models with HYDRA-MATIC 4L60-E Transmission (RPO M30) and with 2.2L, 3.8L, 4.3L, 5.0L or 5.7L Engine (VINs 4, G, K, W, X, M, R - RPOs LN2, LS1, L36, L35, LF6, L30, L31, L05) This bulletin contains information regarding new service tools which are now available from Kent-Moore. These tools will aid in oil cooler flushing and flow checking procedures. 4T40-E (Figure 1) A new cooler flush adapter tool J 35944-440 is available from Kent-Moore to aid in attaching the 4T40-E cooler lines to the existing Kent-Moore cooler flushing tool J 35944-A. A new cooler flow adapter tool J 42776 is available from Kent-Moore to aid in capturing return oil from the radiator during oil flow checking procedures. Disconnect the return cooler line at the radiator and install the cooler flow adapter tool J 42776 to the radiator to aid in capturing the transmission oil. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 6862 4L60-E (Figure 2) A new cooler flush adapter tool J 35944-200 is available from Kent-Moore to aid in attaching the 4L60-E quick connect cooler lines to the existing Kent-Moore cooler flushing tool J 35944-A. Cooler Flushing The transmission oil cooler must be flushed whenever a transmission is removed from the vehicle for service or if fluid contamination is suspected. Use the Kent-Moore tool J 35944-A and solvent J 35944-22 to flush the cooler. Instructions for using the cooler flushing tool and performing fluid flow check may be found in the On-Vehicle Service Section of the service manual or may be found on a Corporate Service Bulletin 77-71-59. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 3T40 Transmission Cooler: Service and Repair 3T40 ^ Tools Required: J 35944 Cooler Flushing Tool - J 35944-20 Flushing Solution Water Supply - Air Supply (with water and oil filter) - Oil Drain Container 5 Gallon Pail 1. Remove the fill cap on J 35944 and fill with 0.6 liter (20-21 ounces) of J 35944-20 flushing solution. - Do not overfill. - Follow manufacturer's suggested procedures for solution handling. 2. Replace cap on J 35944 and pressurize it to 550-700 kPa (80-100 psi.). 3. Connect J 35944 to the transaxle end of the transaxle cooler pipe that feeds the BOTTOM fitting of the oil cooler. 4. Connect the discharge hose to the TOP oil cooler pipe and clip the discharge hose to oil drain container. 5. With the water valve on J 35944 in the "Off" position, connect the water supply to the tool. 6. Turn the water supply on. 7. Flush the transaxle oil by opening the water valve to the "On" position for about 10 seconds. Important If water does not flow through the cooler the system is completely plugged. Do not complete the flushing procedure. Replace the cooler and/or the cooler pipes as required. 8. Close the water valve and clip the discharge hose to the five gallon pail. Cover the pail with a shop towel to prevent splash. 9. Turn the water valve to the "On" position and depress the trigger to mix flushing solution into the water flow. Use the bale clip provided to hold the trigger down. 10. Flush the cooler with water and solution for 2 minutes. During this flush, attach the air supply to the air valve located on the tool for 3 to 5 seconds every 15-20 seconds. This will create a surging action to ensure complete cleaning. 11. Release the trigger and turn the water valve off. 12. Disconnect both hoses from the oil cooler pipes. 13. Reconnect the hoses to the pipes opposite the initial flush to perform a backflush. 14. Repeat Steps 9 and 10. 15. Release the trigger and allow water to rinse for one minute. 16. Turn the water valve off. 17. Attach the air supply to the air valve and dry the system out with air until no moisture is seen leaving the discharge hose. 18. Connect the cooler feed pipe to the transaxle. The cooler feed is the bottom connection at the transaxle. 19. Clip the discharge hose to the oil drain container. 20. After filling the transaxle with oil, start the engine and run for 30 seconds. This will remove any residual moisture from the oil cooler. A minimum of 2 quarts of oil should flow during the 30 second period. If oil flow is insufficient, check the oil flow by disconnecting the feed line at the cooler and observe the flow with the engine running. Insufficient Flow: inspect the transaxle for causes. Inspect cooler pipes, fittings and repeat cooler flushing procedure. If the flow is still insufficient, replace the cooler. 21. Remove the discharge hose and reconnect the cooler pipe. Adjust oil level as needed. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 3T40 > Page 6865 Transmission Cooler: Service and Repair 4T40-E ^ Tools Required: J 35944 Cooler Flushing Tool - J 35944-20 Flushing Solution Water Supply - Air Supply (with water and oil filter) - Oil Drain Container 5 Gallon Pail 1. Remove the fill cap on J 35944 and fill with 0.6 liter (20-21 ounces) of J 35944-20 flushing solution. - Do not overfill. - Follow manufacturer's suggested procedures for solution handling. 2. Replace cap on J 35944 and pressurize it to 550-700 kPa (80-100 psi.). 3. Connect J 35944 to the transaxle end of the transaxle cooler pipe that feeds the BOTTOM fitting of the oil cooler. 4. Connect the discharge hose to the TOP oil cooler pipe and clip the discharge hose to oil drain container. 5. With the water valve on J 35944 in the "Off" position, connect the water supply to the tool. 6. Turn the water supply on. 7. Flush the transaxle oil by opening the water valve to the "On" position for about 10 seconds. Important If water does not flow through the cooler the system is completely plugged. Do not complete the flushing procedure. Replace the cooler and/or the cooler pipes as required. 8. Close the water valve and clip the discharge hose to the five gallon pail. Cover the pail with a shop towel to prevent splash. 9. Turn the water valve to the "On" position and depress the trigger to mix flushing solution into the water flow. Use the bale clip provided to hold the trigger down. 10. Flush the cooler with water and solution for 2 minutes. During this flush, attach the air supply to the air valve located on the tool for 3 to 5 seconds every 15-20 seconds. This will create a surging action to ensure complete cleaning. 11. Release the trigger and turn the water valve off. 12. Disconnect both hoses from the oil cooler pipes. 13. Reconnect the hoses to the pipes opposite the initial flush to perform a backflush. 14. Repeat Steps 9 and 10. 15. Release the trigger and allow water to rinse for one minute. 16. Turn the water valve off. 17. Attach the air supply to the air valve and dry the system out with air until no moisture is seen leaving the discharge hose. 18. Connect the cooler feed pipe to the transaxle. The cooler feed is the bottom connection at the transaxle. 19. Clip the discharge hose to the oil drain container. 20. After filling the transaxle with oil, start the engine and run for 30 seconds. This will remove any residual moisture from the oil cooler. A minimum of 2 quarts of oil should flow during the 30 second period. If oil flow is insufficient, check the oil flow by disconnecting the feed line at the cooler and observe the flow with the engine running. Insufficient Flow: inspect the transaxle for causes. Inspect cooler pipes, fittings and repeat cooler flushing procedure. If the flow is still insufficient, replace the cooler. 21. Remove the discharge hose and reconnect the cooler pipe. Adjust oil level as needed. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 Transmission Mount: Service and Repair 3T40 Transaxle Mount ^ Tool Required: J 28467-360 Engine Support Fixture REMOVE OR DISCONNECT 1. Negative battery cable. 2. Install engine support fixture J 28467-360. Raise transaxle enough to unload transaxle mounts. 3. Raise and support the vehicle. 4. Left front wheel and tire assembly. 5. Left splash shield. 6. Pipe expansion bolt from transaxle support assembly. 7. Transaxle mount to body bolts. 8. Lower engine/transaxle assembly just enough to be able to remove transaxle mount from bracket. 9. Transaxle mount. INSTALL OR CONNECT 1. Transaxle mount to transaxle bracket. Do not tighten until mount is fastened to body. 2. Raise engine/transaxle assembly. 3. Transaxle mount to body bolts. 4. Pipe expansion bolt to transaxle support assembly. 5. Left splash shield. 6. Left front wheel and tire assembly. 7. Remove engine support fixture J 28467-360. 8. Negative battery cable. Transaxle Support Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 > Page 6870 ^ Tool Required: J 28467-360 Engine Support Fixture REMOVE OR DISCONNECT 1. Negative battery cable. 2. Air intake duct. 3. TV cable, refer to "TV Cable Replacement." 4. Power brake booster line and hose. 5. Install engine support fixture J 28467-360. Raise engine enough to take pressure from engine mounts. 6. Raise and support the vehicle. 7. Engine mount strut. 8. Left front wheel and tire assembly. 9. Left splash shield. 10. Crossmember. 11. Left front ABS wheel speed sensor connector and harness from suspension support. 12. Left front ball joint. 13. Left stabilizer bushing nuts. 14. Stabilizer shaft from left lower control arm. 15. Left suspension support. 16. Left side drive axle from transaxle. 17. Transaxle cooler pipes and plug to prevent leakage. 18. P/S lines from P/S gear and plug to prevent leakage. 19. Transaxle mount to body bolts. 20. Pipe expansion bolt from transaxle support assembly, refer to the image. 21. Lower engine/transaxle assembly just enough to be able to remove transaxle support assembly and mount assembly. 22. Transaxle mount from transaxle support assembly. 23. Transaxle support assembly fasteners. 24. Transaxle support assembly. INSTALL OR CONNECT 1. Position transaxle support assembly in vehicle and tighten fasteners. 2. Transaxle mount to transaxle support assembly. 3. Raise engine/transaxle assembly. 4. Transaxle mount to body bolts. Refer to image. 5. Transaxle pipe expansion bolt to transaxle support assembly. 6. P/S lines to P/S gear, refer to Steering and Suspension. 7. Transaxle cooler lines, refer to Transaxle Cooler Lines." 8. Drive axle to transaxle, refer Steering and Suspension. 9. Left suspension support, refer to Steering and Suspension. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 > Page 6871 10. Stabilizer shaft to left lower control arm. 11. Left stabilizer bushing nuts. 12. Left front ball joint. 13. Route and connect left front ABS wheel speed sensor. 14. Crossmember. 15. Left splash shield. 16. Left front wheel and tire assembly, refer to Steering and Suspension. 17. Engine mount strut, refer to Engine Mechanical. 18. Lower vehicle. 19. Remove engine support fixture J 28467-360. 20. Power brake booster line and hose. 21. TV cable, refer to "TV Cable Replacement." 22. Air intake duct. 23. Negative battery cable. Adjust - P/S oil level. Refer to Steering and Suspension for checking and adding oil procedure. - TV cable, refer to "TV Cable Adjustment." - Oil level, refer to "Transaxle Oil Level Checking Procedure." Inspect - Suspension alignment. - For oil leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 > Page 6872 Transmission Mount: Service and Repair 4T40-E Transaxle Mount ^ Tool Required: J 28467-360 Engine Support Fixture REMOVE OR DISCONNECT 1. Negative battery cable. 2. Install engine support fixture, J 28467-360. 3. Upper transaxle mount assembly bolts. 4. Raise and support the vehicle. 5. Left front tire and wheel assembly. 6. Left front splash shield. 7. Transaxle mount expansion pipe bolt. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 > Page 6873 8. Lower transaxle mount assembly bolts. 9. Transaxle mount. INSTALL OR CONNECT 1. Transaxle mount. 2. Lower transaxle mount bolts. 3. Transaxle mount expansion plug. 4. Left front splash shield. 5. Left front tire and wheel assembly, refer to Steering and Suspension. 6. Lower vehicle. 7. Upper transaxle mount assembly bolts. 8. Remove engine support fixture. 9. Negative battery cable. Transaxle Support Assembly ^ Tool Required: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 > Page 6874 - J 28467-360 Engine Support Fixture REMOVE OR DISCONNECT 1. Negative battery cable. 2. Install engine support fixture, J 28467-360. 3. Upper transaxle support assembly bolts. 4. Raise and support the vehicle. 5. Left front tire and wheel assembly. 6. Left front splash shield. 7. Transaxle mount expansion pipe bolt. 8. Lower transaxle support assembly bolts. 9. Transaxle support. INSTALL OR CONNECT 1. Transaxle Support. 2. Lower transaxle support bolts. 3. Transaxle mount expansion plug. 4. Left front splash shield. 5. Left front tire and wheel assembly, refer to Steering and Suspension. 6. Lower vehicle. 7. Upper transaxle support assembly bolts. 8. Remove engine support fixture. 9. Negative battery cable. Transaxle Brace REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise and support the vehicle. 3. Right front tire and wheel assembly. 4. Right front splash shield. 5. Transaxle brace bolts. 6. Transaxle brace. INSTALL OR CONNECT 1. Transaxle brace. 2. Transaxle brace to engine bolts. 3. Transaxle brace to transaxle bolts. 4. Right front splash shield. 5. Right front tire and wheel assembly, refer to Steering and Suspension. 6. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 3T40 > Page 6875 7. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6884 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6885 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6891 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 6892 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 6904 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6905 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6906 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6907 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6910 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6911 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 6912 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: Customer Interest A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6921 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6922 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6923 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6924 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6925 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6926 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: All Technical Service Bulletins A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6936 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6937 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6938 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6939 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6940 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 6941 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Ball Check Valve Locations Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Ball Check Valve Locations > Page 6949 Valve Body: Locations Control Valve Body Assembly Part 1 Of 2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Ball Check Valve Locations > Page 6950 Part 2 Of 2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > LO and Reverse Pipes and Cup Plug Valve Body: Service and Repair LO and Reverse Pipes and Cup Plug REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Oil pan. 3. Oil strainer and seal. 4. Reverse oil pipe, seal back-up ring and O-ring seal. 5. Low and reverse cup plug assembly using screw extractor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > LO and Reverse Pipes and Cup Plug > Page 6953 INSTALL OR CONNECT 1. Low and reverse cup plug assembly. 2. Reverse oil pipe and seal back-up ring with a new "O" ring. 3. Oil strainer with a new seal. 4. Oil pan. 5. Lower vehicle. Inspect - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > LO and Reverse Pipes and Cup Plug > Page 6954 Valve Body: Service and Repair Auxiliary Valve Body, Valve Body Pump REMOVE OR DISCONNECT 1. Negative battery cable. 2. TV cable from transaxle, refer to "TV Cable Replacement." 3. Valve body cover. Refer to "Transaxle Mount, Bracket, Valve Body Cover and Case Cover." 4. Bolt securing TCC solenoid to auxiliary valve body and solenoid. Remove TCC solenoid wiring connector from case connector. 5. TCC wires from pressure switches. 6. Bolt securing TV linkage and bracket assembly to valve body and TV linkage. 7. Remaining bolts securing valve body to case cover and valve body. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > LO and Reverse Pipes and Cup Plug > Page 6955 Important Do not lose the six check balls. - Do not remove the green bolt. 8. Green bolt and separate auxiliary valve body from valve body. 9. Check ball behind control valve assembly. Important If any service is required on the valve body and/or oil pump, refer to Valve Body Unit Repair. INSTALL OR CONNECT 1. Check valve behind control valve assembly. 2. Auxiliary valve body to valve body with green bolt. 3. Check ball in valve body. Refer to the image. 5. Valve body to case cover. 6. TV bracket and linkage. 7. TCC wires and wiring connectors. 8. TCC solenoid. 9. Valve body cover with a new gasket. Refer to "Transaxle mount, Bracket, Valve Body Cover and Case Cover." 10. TV cable to transaxle, refer to "TV Cable Replacement." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > LO and Reverse Pipes and Cup Plug > Page 6956 11. Negative battery cable. Adjust - TV cable, refer to "TV Cable Adjustment." - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > LO and Reverse Pipes and Cup Plug > Page 6957 Valve Body: Service and Repair Torque Converter Clutch (TCC) Solenoid and Switches REMOVE OR DISCONNECT 1. Valve body cover. 2. Wiring harness from case electrical connector and leads from pressure switch. 3. Torque converter clutch solenoid bolt to auxiliary valve body. 4. 3rd clutch pressure switch. 5. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. Tighten Tighten to 12 N.m (124 lb. in.). 2. 3rd clutch pressure switch. Tighten Tighten to 12 N.m (124 lb. in.). 3. Torque converter clutch solenoid bolt to auxiliary valve body. Install new "O" ring. Tighten Tighten to 12 N.m (124 lb. in.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair ^ Tool Required: J 29074 Clutch Alignment Arbor REMOVE OR DISCONNECT 1. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 6962 2. Clutch master cylinder assembly from clutch actuator cylinder assembly. 3. Transaxle assembly. 4. Clutch cover bolts one turn at a time, until spring pressure is relieved. 5. Clutch cover and clutch disc. Clean - Clutch cover and flywheel mating surfaces and the bearing retainer outer surface of all oil, grease, metal deposits, etc. INSTALL OR CONNECT 1. Align the "Heavy Side" of the flywheel assembly, stamped with an "X", with the clutch cover "Light Side" marked with paint. Support with J 29074. The clutch disc is installed with the damper springs offset toward the transaxle. Stamped letters on the clutch disc identify "Flywheel side". 2. Clutch cover assembly-to-flywheel bolts evenly following the below tightening sequence: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 6963 - Install and tighten bolts 1, 2, 3 then 4, 5, 6, to 16 N.m (12 lb. ft.) in order. Tighten bolts 1, 2, 3 then 4, 5, 6 to specifications, refer to "Specifications." Remove J 29074. 3. Lubricate the inside diameter of the bearing with clutch bearing lubricant GM P/N 12345777 or equivalent. 4. Transaxle. 5. Clutch master cylinder assembly to clutch actuator cylinder assembly. 6. Bleed hydraulic system, refer to "Hydraulic System Bleeding Procedure." 7. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair REMOVE OR DISCONNECT 1. Negative battery cable. 2. Sound insulator from inside the vehicle. 3. Clutch master cylinder pushrod from the clutch pedal. 4. Clutch master cylinder retaining nuts at front of dash. 5. Remote reservoir. 6. Clutch master cylinder assembly from clutch actuator cylinder assembly, refer to the image. INSTALL OR CONNECT 1. Clutch master cylinder assembly to clutch actuator cylinder assembly, refer to last image. 2. Remote reservoir. 3. Clutch master cylinder retaining nuts at front of dash. Tighten Nuts evenly to 21 N.m (15 lb. ft.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 6968 4. Pushrod to clutch pedal. Important Cruise control clutch switch if equipped. 5. Sound insulator. 6. Bleed hydraulic system, refer to "Hydraulic System Bleeding Procedure." 7. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 6972 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 6973 REMOVE OR DISCONNECT 1. Negative battery cable. 2. Clutch master cylinder assembly from clutch actuator cylinder assembly. 3. Transaxle assembly. 4. Clutch actuator cylinder assembly from transaxle. INSTALL OR CONNECT 1. Lubricate the inside diameter of the bearing with clutch bearing lubricant GM P/N 12345777 or equivalent. 2. Clutch actuator cylinder assembly to transaxle. 3. Transaxle assembly. 4. Clutch master cylinder assembly to clutch actuator cylinder assembly. 5. Bleed hydraulic system, refer to "Hydraulic System Bleeding Procedure." 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Locations > Page 6977 Clutch Pedal Assembly: Service and Repair Important - The clutch pedal and bracket are serviced as an assembly. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Sound insulator from inside the vehicle. 3. Clutch master cylinder pushrod from the clutch pedal. 4. Clutch pedal and bracket mounting nuts. 5. Clutch pedal and bracket assembly. INSTALL OR CONNECT 1. Clutch pedal and bracket assembly. 2. Clutch pedal and bracket mounting nuts. Tighten Nuts to 23 N.m (17 lb. ft.) starting with the lower nuts. 3. Clutch master cylinder pushrod bushing on the pedal. - Lubricate the bushing. 4. Clutch master cylinder pushrod to the clutch pedal. Adjust - Cruise control clutch switch if equipped, refer to Powertrain Management. 5. Sound insulator. 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 6981 Clutch Switch: Service and Repair REMOVE OR DISCONNECT 1. Wire harness connector from clutch pedal position switch. 2. Clutch pedal position switch from clutch pedal assembly. INSTALL OR CONNECT 1. Clutch pedal position switch to clutch pedal assembly. 2. Wire harness connector to clutch pedal position switch. 3. Verify proper operation of switch. The starter should engage only when clutch is fully disengaged. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch Cover to Flywheel Bolt ............................................................................................................. ..................................................... 20 N.m (15 lb. ft.) Plus Rotate .......................................................................................................................................... .......................................................................... 45° Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6985 Pressure Plate: Service and Repair ^ Tool Required: J 29074 Clutch Alignment Arbor REMOVE OR DISCONNECT 1. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6986 2. Clutch master cylinder assembly from clutch actuator cylinder assembly. 3. Transaxle assembly. 4. Clutch cover bolts one turn at a time, until spring pressure is relieved. 5. Clutch cover and clutch disc. Clean - Clutch cover and flywheel mating surfaces and the bearing retainer outer surface of all oil, grease, metal deposits, etc. INSTALL OR CONNECT 1. Align the "Heavy Side" of the flywheel assembly, stamped with an "X", with the clutch cover "Light Side" marked with paint. Support with J 29074. The clutch disc is installed with the damper springs offset toward the transaxle. Stamped letters on the clutch disc identify "Flywheel side". 2. Clutch cover assembly-to-flywheel bolts evenly following the below tightening sequence: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6987 - Install and tighten bolts 1, 2, 3 then 4, 5, 6, to 16 N.m (12 lb. ft.) in order. Tighten bolts 1, 2, 3 then 4, 5, 6 to specifications, refer to "Specifications." Remove J 29074. 3. Lubricate the inside diameter of the bearing with clutch bearing lubricant GM P/N 12345777 or equivalent. 4. Transaxle. 5. Clutch master cylinder assembly to clutch actuator cylinder assembly. 6. Bleed hydraulic system, refer to "Hydraulic System Bleeding Procedure." 7. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair ^ Tool Required: J 36660 - Or Equivalent REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Support rear axle assembly with jackstands. 3. Rear tire and wheel assembly. 4. Disconnect the brake pipe at the brake pipe brackets on the axle assembly. This will ensure that the axle assembly is not suspended by the brake pipes and hoses. 5. Lower coil-over shock mount bolt. 6. Lower the rear axle. 7. Parking brake cable at equalizer unit and right rear wheel assembly. 8. Disconnect rear ABS wiring connector and mount clip located near the fuel tank. 9. Right and left brake lines. 10. Control arm bolts and nuts. 11. Axle assembly. INSTALL OR CONNECT 1. Position rear axle assembly, and loosely install attaching bolts. 2. Right and left brake lines. 3. ABS wiring connector and mount clip. 4. Parking brake cable at right rear wheel cable connector and cable equalizer. 5. Lower coil-over shock mount bolt. ^ Tighten: Control arm nuts 60 Nm (44 ft. lbs.) plus 120° rotation using J 36660. - Shock absorber lower attaching bolt and nut to 170 Nm (125 ft. lbs.). 6. Left and right side brake line bracket mount bolts to body. ^ Tighten screws to 11 Nm (97 inch lbs.). 7. Install tire and wheel assembly. 8. Jackstands from underneath vehicle. 9. Lower vehicle. 10. Fill and bleed rear brake system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > A/T - Transaxle Stub Shaft Disengagement Axle Shaft: Technical Service Bulletins A/T - Transaxle Stub Shaft Disengagement File In Section: 7 - Transmission Bulletin No.: 57-71-11A Date: September, 1996 INFORMATION Subject: Transaxle Stub Shaft Disengages from the Transaxle During Axle Tripot Removal Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and 2.2L, 2.3L, 2.4L Engine (VINs 4, D, T - RPOs LN2, LD2, LD9) This bulletin is being revised to update models and Include mandatory replacement of the axle seal. Please discard Corporate Bulletin Number 57-71-11 (Section 7 - Transmission.) The transaxle stub shaft may disengage from the transaxle during axle tripot removal. If this condition occurs, transaxle fluid may leak from the transaxle through the stub shaft location. Remove the stub shaft from the axle tripot and reassemble the stub shaft and sleeve assembly into the transaxle using the following procedure: Important: If this condition exists, it is mandatory that the axle seal (2) be replaced with a new axle seal. Be careful not to damage the stub shaft sleeve (56) during the following procedure or an axle seal leak may develop. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > A/T - Transaxle Stub Shaft Disengagement > Page 7003 1. Remove the snap ring (57) from the stub shaft (58). Discard the snap ring after removal from the stub shaft. The snap ring is not reusable once it is removed from the shaft. (See Figure 3) 2. Connect the stub shaft removal tool (J 38868) to the snap ring groove on the stub shaft and remove the shaft from the tripot with a slide hammer (J 6125-1 B) impact. Support the tripot during stub shaft removal to prevent damage to the tripot. (See Figure 2) 3. Remove and install a new right hand axle seal onto the transaxle (See Figure 3). Refer to the On Vehicle Service Manual for the proper procedure. 4. Inspect the stub shaft sleeve (56) for excessive wear, nicks or scratches, and for damage to the seal portion. If these occur, replace the sleeve (56) following the service procedure found in the Unit Repair Section of the Service Manual. Important: The sleeve should be square to the stub shaft (58). 5. Install a new snap ring (57) onto the stub shaft (58) and install the stub shaft into the transaxle. (See Figure 3) 6. Grease the splines on the outer end of the stub shaft with Polyurea grease (Part Number 7847638) prior to installing the tripot (see Figure 3). Use approximately 3 grams of grease and be sure to cover the entire spline area. This grease must be added to prevent corrosion to the shaft splines. Do Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Technical Service Bulletins > A/T - Transaxle Stub Shaft Disengagement > Page 7004 not add grease to the end of the stub shaft that inserts into the transaxle. 7. Reset the transaxle fluid level (refer to the appropriate Service Manual for detailed fluid level service procedures). Parts Information Part Illustration Number Description Number 24201936 Axle Seal 2 7829495 Stub Shaft Snap Ring 57 7847638 Polyurea Grease (133 gram bag) Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time Right stub shaft sleeve K6925 and/or output stub shaft 0.8 hr replace Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest: > 637205 > Jan > 97 > Axle Seal Area Leak Seals and Gaskets: Customer Interest Axle Seal Area - Leak File In Section: 7 - Transmission Bulletin No.: 63-72-05 Date: January, 1997 Subject: Leak in the Axle Seal Area (Shorten Vent Hose) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire with Manual Transaxle Condition Some owners may comment on a leak in the axle seal area. Cause The transaxle vent hose may be pinched between the air cleaner and strut tower. Correction To correct this condition, shorten the vent hose which is 254 mm (10 inches) to 165 to 178 mm (6 1/2 to 7 inches) and re-install. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time K2570 0.3 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 637205 > Jan > 97 > Axle Seal Area - Leak Seals and Gaskets: All Technical Service Bulletins Axle Seal Area - Leak File In Section: 7 - Transmission Bulletin No.: 63-72-05 Date: January, 1997 Subject: Leak in the Axle Seal Area (Shorten Vent Hose) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire with Manual Transaxle Condition Some owners may comment on a leak in the axle seal area. Cause The transaxle vent hose may be pinched between the air cleaner and strut tower. Correction To correct this condition, shorten the vent hose which is 254 mm (10 inches) to 165 to 178 mm (6 1/2 to 7 inches) and re-install. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time K2570 0.3 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 577111A > Sep > 96 > A/T - Transaxle Stub Shaft Disengagement Seals and Gaskets: All Technical Service Bulletins A/T - Transaxle Stub Shaft Disengagement File In Section: 7 - Transmission Bulletin No.: 57-71-11A Date: September, 1996 INFORMATION Subject: Transaxle Stub Shaft Disengages from the Transaxle During Axle Tripot Removal Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and 2.2L, 2.3L, 2.4L Engine (VINs 4, D, T - RPOs LN2, LD2, LD9) This bulletin is being revised to update models and Include mandatory replacement of the axle seal. Please discard Corporate Bulletin Number 57-71-11 (Section 7 - Transmission.) The transaxle stub shaft may disengage from the transaxle during axle tripot removal. If this condition occurs, transaxle fluid may leak from the transaxle through the stub shaft location. Remove the stub shaft from the axle tripot and reassemble the stub shaft and sleeve assembly into the transaxle using the following procedure: Important: If this condition exists, it is mandatory that the axle seal (2) be replaced with a new axle seal. Be careful not to damage the stub shaft sleeve (56) during the following procedure or an axle seal leak may develop. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 577111A > Sep > 96 > A/T - Transaxle Stub Shaft Disengagement > Page 7022 1. Remove the snap ring (57) from the stub shaft (58). Discard the snap ring after removal from the stub shaft. The snap ring is not reusable once it is removed from the shaft. (See Figure 3) 2. Connect the stub shaft removal tool (J 38868) to the snap ring groove on the stub shaft and remove the shaft from the tripot with a slide hammer (J 6125-1 B) impact. Support the tripot during stub shaft removal to prevent damage to the tripot. (See Figure 2) 3. Remove and install a new right hand axle seal onto the transaxle (See Figure 3). Refer to the On Vehicle Service Manual for the proper procedure. 4. Inspect the stub shaft sleeve (56) for excessive wear, nicks or scratches, and for damage to the seal portion. If these occur, replace the sleeve (56) following the service procedure found in the Unit Repair Section of the Service Manual. Important: The sleeve should be square to the stub shaft (58). 5. Install a new snap ring (57) onto the stub shaft (58) and install the stub shaft into the transaxle. (See Figure 3) 6. Grease the splines on the outer end of the stub shaft with Polyurea grease (Part Number 7847638) prior to installing the tripot (see Figure 3). Use approximately 3 grams of grease and be sure to cover the entire spline area. This grease must be added to prevent corrosion to the shaft splines. Do Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 577111A > Sep > 96 > A/T - Transaxle Stub Shaft Disengagement > Page 7023 not add grease to the end of the stub shaft that inserts into the transaxle. 7. Reset the transaxle fluid level (refer to the appropriate Service Manual for detailed fluid level service procedures). Parts Information Part Illustration Number Description Number 24201936 Axle Seal 2 7829495 Stub Shaft Snap Ring 57 7847638 Polyurea Grease (133 gram bag) Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time Right stub shaft sleeve K6925 and/or output stub shaft 0.8 hr replace Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 577111A > Sep > 96 > A/T - Transaxle Stub Shaft Disengagement Seals and Gaskets: All Technical Service Bulletins A/T - Transaxle Stub Shaft Disengagement File In Section: 7 - Transmission Bulletin No.: 57-71-11A Date: September, 1996 INFORMATION Subject: Transaxle Stub Shaft Disengages from the Transaxle During Axle Tripot Removal Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire with HYDRA-MATIC 4T40-E Transaxle (RPO MN4) and 2.2L, 2.3L, 2.4L Engine (VINs 4, D, T - RPOs LN2, LD2, LD9) This bulletin is being revised to update models and Include mandatory replacement of the axle seal. Please discard Corporate Bulletin Number 57-71-11 (Section 7 - Transmission.) The transaxle stub shaft may disengage from the transaxle during axle tripot removal. If this condition occurs, transaxle fluid may leak from the transaxle through the stub shaft location. Remove the stub shaft from the axle tripot and reassemble the stub shaft and sleeve assembly into the transaxle using the following procedure: Important: If this condition exists, it is mandatory that the axle seal (2) be replaced with a new axle seal. Be careful not to damage the stub shaft sleeve (56) during the following procedure or an axle seal leak may develop. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 577111A > Sep > 96 > A/T - Transaxle Stub Shaft Disengagement > Page 7029 1. Remove the snap ring (57) from the stub shaft (58). Discard the snap ring after removal from the stub shaft. The snap ring is not reusable once it is removed from the shaft. (See Figure 3) 2. Connect the stub shaft removal tool (J 38868) to the snap ring groove on the stub shaft and remove the shaft from the tripot with a slide hammer (J 6125-1 B) impact. Support the tripot during stub shaft removal to prevent damage to the tripot. (See Figure 2) 3. Remove and install a new right hand axle seal onto the transaxle (See Figure 3). Refer to the On Vehicle Service Manual for the proper procedure. 4. Inspect the stub shaft sleeve (56) for excessive wear, nicks or scratches, and for damage to the seal portion. If these occur, replace the sleeve (56) following the service procedure found in the Unit Repair Section of the Service Manual. Important: The sleeve should be square to the stub shaft (58). 5. Install a new snap ring (57) onto the stub shaft (58) and install the stub shaft into the transaxle. (See Figure 3) 6. Grease the splines on the outer end of the stub shaft with Polyurea grease (Part Number 7847638) prior to installing the tripot (see Figure 3). Use approximately 3 grams of grease and be sure to cover the entire spline area. This grease must be added to prevent corrosion to the shaft splines. Do Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 577111A > Sep > 96 > A/T - Transaxle Stub Shaft Disengagement > Page 7030 not add grease to the end of the stub shaft that inserts into the transaxle. 7. Reset the transaxle fluid level (refer to the appropriate Service Manual for detailed fluid level service procedures). Parts Information Part Illustration Number Description Number 24201936 Axle Seal 2 7829495 Stub Shaft Snap Ring 57 7847638 Polyurea Grease (133 gram bag) Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time Right stub shaft sleeve K6925 and/or output stub shaft 0.8 hr replace Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 7031 Seals and Gaskets: By Symptom Technical Service Bulletin # 637205 Date: 970101 Axle Seal Area - Leak File In Section: 7 - Transmission Bulletin No.: 63-72-05 Date: January, 1997 Subject: Leak in the Axle Seal Area (Shorten Vent Hose) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire with Manual Transaxle Condition Some owners may comment on a leak in the axle seal area. Cause The transaxle vent hose may be pinched between the air cleaner and strut tower. Correction To correct this condition, shorten the vent hose which is 254 mm (10 inches) to 165 to 178 mm (6 1/2 to 7 inches) and re-install. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time K2570 0.3 hr Technical Service Bulletin # 637205 Date: 970101 Axle Seal Area - Leak File In Section: 7 - Transmission Bulletin No.: 63-72-05 Date: January, 1997 Subject: Leak in the Axle Seal Area (Shorten Vent Hose) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire with Manual Transaxle Condition Some owners may comment on a leak in the axle seal area. Cause The transaxle vent hose may be pinched between the air cleaner and strut tower. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 7032 To correct this condition, shorten the vent hose which is 254 mm (10 inches) to 165 to 178 mm (6 1/2 to 7 inches) and re-install. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time K2570 0.3 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 7036 Wheel Bearing: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 7037 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension FRONT WHEEL BEARINGS AND/OR HUB ^ Tools Required: J 28733-A Front Hub Spindle Remover REMOVE OR DISCONNECT 1. Drive axle. 2. Brake caliper bolts, and support caliper. 3. Rotor. 4. Hub and bearing assembly. 5. Hub and bearing assembly from steering knuckle. 6. Hub and bearing. INSTALL OR CONNECT 1. Hub and bearing assembly to steering knuckle. 2. Hub and bearing assembly bolts. ^ Tighten hub and bearing assembly bolts to 95 Nm (70 ft. lbs.). 3. Rotor. 4. Brake caliper and bolts. 5. New hub and bearing into steering knuckle. 6. Drive axle. 7. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 7040 Wheel Bearing: Service and Repair Rear Suspension REAR WHEEL BEARINGS AND/OR HUB REMOVE OR DISCONNECT 1. Raise vehicle. 2. Wheel and tire assemblies. 3. Brake drum. NOTICE: Do not hammer on brake drum as damage to the assembly could result. 4. Rear ABS wheel speed sensor wire connector. 5. Remove hub and bearing assembly from axle. The top rear attaching bolt/nut will not clear the brake shoe when removing the hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. INSTALL OR CONNECT 1. Connect rear ABS wheel speed sensor wire connector. 2. Hub and Bearing assembly. Position top rear attaching bolt in hub and bearing assembly prior to the installation in the axle assembly. ^ Tighten hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). 3. Brake drum. 4. Wheel and tire assembly. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Steering - Various Revised Tightening Specifications Axle Nut: Technical Service Bulletins Steering - Various Revised Tightening Specifications CHEVROLET 73-32-03A Issued: 05/01/97 SMU - SECTIONS 3B/3C/4D REVISION: 04/11/97 THIS BULLETIN IS BEING REVISED TO UPDATE THE DRIVE AXLE NUT TIGHTENING SPECIFICATIONS FOR THE N CAR. PLEASE DISCARD CORPORATE BULLETIN NUMBER 73-32-03 (SECTION 3 - STEERING/SUSPENSION). SUBJECT: SERVICE MANUAL UPDATE - SECTIONS 3B/3C/4D - REVISED TIGHTENING SPECIFICATIONS MODELS: 1997 CHEVROLET CAVALIER, MALIBU 1997 OLDSMOBILE CUTLASS 1997 PONTIAC SUNFIRE THIS BULLETIN IS BEING ISSUED TO REVISE THE TIGHTENING SPECIFICATIONS IN SECTIONS 3B, 3C AND 4D OF THE SERVICE MANUAL AS FOLLOWS: J CAR SECTIONS 3B-8, 3B-9, 3C-5 AND 3C-13: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 90 DEGREE ROTATION. N CAR SECTIONS 3C-6 AND 3C-16: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 180 DEGREE ROTATION. SECTION 3B-12: THE CORRECT TIGHTENING SPECIFICATIONS ARE AS FOLLOWS: - STEERING COLUMN LOWER PINCH BOLT 22 N.M (16 LB FT) - STEERING COLUMN UPPER PINCH BOLT 22 N.M (16 LB FT) SECTIONS 3C-16, 4D-4 AND 4D-5: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - FRONT DRIVE AXLE NUT 385 N.M (284 LB FT) +/- 5 N.M (44 LB IN). REPLACE THE DRIVE AXLE NUT WITH A NEW ONE AFTER EVERY REMOVAL. NEVER RE-USE THE DRIVE AXLE NUT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 7046 Axle Nut: Specifications Service Manual Update # 73-32-03A Drive Axle Nut (New) ............................................................................................................................................... 385 Nm (284 lb ft) +/- 5 Nm (44 lb in) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Component Information > Technical Service Bulletins > Tire/Wheel and Propshaft - Revised Rotational Worksheet Drive/Propeller Shafts, Bearings and Joints: Technical Service Bulletins Tire/Wheel and Propshaft Revised Rotational Worksheet File In Section: 0 - General Information Bulletin No.: 63-01-03 Date: January, 1997 SERVICE MANUAL UPDATE Subject: Section 0C - Revised Tire/Wheel and Propshaft Rotational Worksheet Models: 1997 Passenger Cars (Except Camaro, Catera, Concours, Corvette, DeVille, Eldorado, Firebird, Seville, Trans Am) 1997 Chevrolet Venture 1997 Geo Tracker 1997 Oldsmobile Silhouette 1997 Pontiac Trans Sport This bulletin is being issued to revise the Tire/Wheel and Propshaft Rotational Worksheet in Section 0C of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Component Information > Technical Service Bulletins > Tire/Wheel and Propshaft - Revised Rotational Worksheet > Page 7051 The previously released Tire/Wheel Rotational Worksheet or the Tire/Wheel and Propshaft Rotational Worksheet did not prompt the user to consistently input a standard and/or metric value on the worksheet. This could lead the user to an incorrect diagnosis of a vibration. The included revised worksheet is applicable to front, rear, and four-wheel drive vehicles as it includes the formula for calculating propshaft speed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Tightening Specifications (Flex Plate to Crankshaft) Flex Plate: Specifications Tightening Specifications (Flex Plate to Crankshaft) FASTENER TIGHTENING SPECIFICATIONS Flywheel To Clutch Cover ................................................................................................................................................ 20 + 45° Nm (15 + 45° ft. lbs.) Flywheel To The Converter ......................................................................... ......................................................................................... 66 Nm (49 ft. lbs.) Flywheel To The Crankshaft ............................................................................................................................................. 30 + 45° Nm (22 + 45° ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Testing and Inspection > 3T40 Flex Plate: Testing and Inspection 3T40 1. Start engine. 2. With engine at idle speed and the transaxle in "Park" or "Neutral", observe vibration. 3. Shut off engine. REMOVE OR DISCONNECT a. Converter shield attaching bolts. b. Flywheel to torque converter attaching bolts. c. Rotate torque converter; 120° (1/3 turn). INSTALL OR CONNECT a. Torque converter to flywheel bolts. Apply adhesive/sealant compound GM P/N 12345493 or equivalent to flywheel bolts. Tighten Bolts to 62 N.m (46 lb ft). Hand start and tighten "net slot" bolt first. Hand start and tighten the two remaining bolts. b. Transaxle converter cover bolts. Tighten Bolts to 10 N.m (18 lb ft). 4. Start engine and check for vibration. Repeat this procedure until the best possible balance is obtained by moving flywheel 120°. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Testing and Inspection > 3T40 > Page 7058 Flex Plate: Testing and Inspection 4T40-E 1. Start engine. 2. With engine at idle speed and the transaxle in "Park" or "Neutral", observe vibration. 3. Shut off engine. REMOVE OR DISCONNECT a. Converter shield attaching bolts. b. Flywheel to torque converter attaching bolts. c. Rotate torque converter; 120° (1/3 turn). INSTALL OR CONNECT a. Torque converter to flywheel bolts. Apply adhesive/sealant compound GM P/N 12345493 or equivalent to flywheel bolts. Tighten Bolts to 62 N.m (46 lb ft). Hand start and tighten "net slot" bolt first. Hand start and tighten the two remaining bolts. b. Transaxle converter cover bolts. Tighten Bolts to 10 N.m (18 lb ft). 4. Start engine and check for vibration. Repeat this procedure until the best possible balance is obtained by moving flywheel 120°. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Testing and Inspection > Page 7059 Flex Plate: Service and Repair REMOVE OR DISCONNECT 1. Raise and support the vehicle. 2. Transaxle converter cover bolts and cover, refer to the image. 3. Mark relationship of converter to flywheel. 4. Three bolts attaching converter to flywheel. INSTALL OR CONNECT 1. Bolts attaching converter to flywheel. Tighten All bolts to 62 N.m (46 lb. ft.). Re-torque the first bolt after all three have been tightened. 2. Converter cover and attaching bolts. Tighten Bolts to 10 N.m (89 lb. in.). 3. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Torque Specifications Flywheel: Specifications Torque Specifications Tighten the bolts to 30 Nm (22 ft. lbs.). Use the torque angle meter in order to rotate the bolts 45 degrees. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The Upshift Indicator is illuminated to indicate optimum shift points for maximum fuel economy. When this light is on, shift transaxle to the next higher gear range, if conditions permit. This indicator is controlled by the IPC as commanded by the PCM via serial data. This telltale will not turn on as result of serial data loss (ignition in OFF/UNLOCK"). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Lube Capacity ...................................................................................................................................... ..................................................... 1.9 liters (2.01 qt.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 7074 Fluid - M/T: Fluid Type Specifications Manual Transaxle .............................................................................................................................................................. Synchromesh Transmission Fluid Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair ^ Tools Required: J 26938 Seal Installer - J 8092 Driver Handle REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise the vehicle. 3. Tire and wheel assembly. 4. Stabilizer shaft from the control arm. 5. Ball joint from the steering knuckle. 6. Drive axle from: - Left oil seal - transaxle. - Right oil seal - intermediate shaft. 7. Intermediate shaft. 8. Drive axle oil seal. - Fill between the seal lips with chassis grease GM P/N 1051344 or equivalent. INSTALL OR CONNECT 1. Drive axle oil seal with J 26938 and J 8092. 2. Intermediate shaft (Right Only). 3. Drive axle. 4. Ball joint to steering knuckle. 5. Stabilizer shaft. 6. Tire and wheel assembly. 7. Lower vehicle. 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control Shifter M/T: Service and Repair Shift Control REMOVE OR DISCONNECT 1. Negative battery cable. 2. Knob, shift boot, and console. Refer to Body and Frame. 3. Shift cables from the pin on the shift control. 4. Spring clip holding the cables to the shift control. 5. Shift control. INSTALL OR CONNECT 1. Shift control. Tighten Control mounting nuts to 25 N.m (18 lb. ft.). 2. Cables to the pin on the shift control. 3. Spring clip that holds the cables to the shift control. 4. Console, shift boot, and knob. Refer to Body and Frame. 5. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control > Page 7082 Shifter M/T: Service and Repair Shift Control Box REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift cables. 3. Control box assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control > Page 7083 Measure - Shift control box. ASSEMBLE 1. Stopper cam and internal lever. REMOVE OR DISCONNECT - Align serrations on the stopper cam and internal lever. 2. Stopper cam and internal lever to the shift lever assembly. Adjust - Alignment of stopper cam with center on internal lever. - Reverse inhibitor mechanism for proper operation. 3. New roll pin to the internal lever. INSTALL OR CONNECT 1. Control box assembly and bolts. Tighten Bolts to 17 N.m (13 lb. ft.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Shift Control > Page 7084 2. Shift cables. Adjust - For proper shifting. 3. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > M/T - Shift Cable Service Clip Shift Cable: Technical Service Bulletins M/T - Shift Cable Service Clip File In Section: 7 - Transmission Bulletin No.: 73-72-01 Date: March, 1997 INFORMATION Subject: Shift Cable Service Clip Models: 1995-97 Chevrolet Cavalier 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am 1995-97 Pontiac Sunfire with Manual Transaxle A clip is available for service use should the clips that attach the shift cables to the shifter and transaxle need replacement. Parts Information Description P/N Spring Clip 22602484 Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Page 7090 Shift Cable: Service and Repair Shift Cables Removal Procedure 1. Disconnect the negative battery cable. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 2. Remove the following parts from the transaxle: 2.1. The cable bracket 2.2. The retaining nut 2.3. The cables 3. Remove the following parts from the control assembly: 3.1. The knob 3.2. The front console 3.3. The shift boot 4. Remove the shift cables from the pin stud on the control assembly. 5. Remove the following parts: 5.1. The spring clip 5.2. The right front sill plate 6. Pull back the carpet in order to access the shift cables. 7. Remove the following parts from the shift cable assembly: 7.1. The grommet cover bolts 7.2. The cable cover 7.3. The cables Installation Procedure Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Page 7091 1. Route the cables. 2. Install the following parts on the cable assembly: 2.1. The cables 2.2. The grommet cable cover 2.3. The attaching bolts at the floor pan Tighten Tighten the bolts to 1.4 Nm (12 lb in). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the cables to the control assembly using adjustable parallel jaw pliers. 4. Install the spring clips that hold the cables to the control assembly. 5. Install the carpet. 6. Install the sill plate. 7. Install the cables on the transaxle. 8. Install the cable bracket. 9. Install the retaining nut. Tighten Tighten the nut to 10 Nm (89 lb in). 10. Connect the cables. 11. Install the following parts on the control assembly: 11.1. The boot 11.2. The front console 11.3. The knob 12. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Front and Rear Transaxle Mounts Transmission Mount: Service and Repair Front and Rear Transaxle Mounts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Front and Rear Transaxle Mounts > Page 7096 ^ Tool Required: J 28467-360 Engine Support Fixture REMOVE OR DISCONNECT 1. Negative battery cable. 2. Install J 28467-360 and raise the engine to take pressure off of the motor mounts. 3. Left wheel. 4. Left splash shield. 5. Through bolt at transaxle mount. 6. Bolts attaching transaxle mount to transaxle. 7. Transaxle mount. INSTALL OR CONNECT 1. Transaxle mount to transaxle and install bolts. Tighten Mount bolts to 75 N.m (55 lb. ft.). 2. Through bolt and nut at transaxle mount. Tighten Through bolt and nut to 60 N.m (44 lb. ft.). 3. Left splash shield. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Front and Rear Transaxle Mounts > Page 7097 Transmission Mount: Service and Repair Checking Transaxle Mounts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Front and Rear Transaxle Mounts > Page 7098 Inspect - Pull up and push down on the transaxle case while observing the mount. If the rubber separates from the metal plate of the mount or if the case moves up, but not down, (mount bottomed out), replace the mount. If there is movement between the metal plate of the mount and its attaching point, tighten the bolts attaching the mount to the mount bracket or side frame. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove Pressure switch assembly, (6 bolts). Important Inspect the O-rings for the pressure switch assembly for any damage. INSTALL OR CONNECT 1. Install the pressure switch assembly making sure all O-rings are in place. 2. Torque the 6 bolts holding the pressure switch assembly to 12 N.m (9 lb. ft.). 3. Install the transaxle case side cover. Refer to "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7118 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7119 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON > Page 7125 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T Shift Flare/DTC's Set/SES Lamp ON > Page 7126 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 7138 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7139 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7140 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7141 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 7144 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 7145 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 7146 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7158 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7159 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7165 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7166 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7172 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 7178 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7179 Pressure Regulating Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Page 7180 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations LH Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT 1. Install the solenoid and O-ring or O-rings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 7187 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 Torque Converter Clutch Solenoid: Service and Repair 3T40 REMOVE OR DISCONNECT 1. Valve body cover. 2. Wiring harness from case electrical connector and leads from pressure switch. 3. Torque converter clutch solenoid bolt to auxiliary valve body. 4. 3rd clutch pressure switch. 5. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. Tighten Tighten to 12 N.m (124 lb. in.). 2. 3rd clutch pressure switch. Tighten Tighten to 12 N.m (124 lb. in.). 3. Torque converter clutch solenoid bolt to auxiliary valve body. Install new "O" ring. Tighten Tighten to 12 N.m (124 lb. in.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Adjust - Oil level. Refer to "Transaxle Oil Level Checking Procedure." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 7192 Torque Converter Clutch Solenoid: Service and Repair 4T40-E REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove retainer clip from the specified solenoid using a small screwdriver. 4. A shift solenoid has one O-ring. The pressure control solenoid and TCC solenoid have 2 O-rings. Remove the solenoid and O-ring or O-rings from transaxle. Important Inspect the O-rings and solenoids for any damage. INSTALL OR CONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > 3T40 > Page 7193 1. Install the solenoid and O-ring or O-rings. 2. Install the retainer clip holding the solenoid in the valve body. 3. Install the transaxle case side cover. See "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The Upshift Indicator is illuminated to indicate optimum shift points for maximum fuel economy. When this light is on, shift transaxle to the next higher gear range, if conditions permit. This indicator is controlled by the IPC as commanded by the PCM via serial data. This telltale will not turn on as result of serial data loss (ignition in OFF/UNLOCK"). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair Fluid Pressure Sensor/Switch: Service and Repair REMOVE OR DISCONNECT 1. Remove negative battery cable. 2. Remove transaxle case side cover. See "Case Side Cover". 3. Remove Pressure switch assembly, (6 bolts). Important Inspect the O-rings for the pressure switch assembly for any damage. INSTALL OR CONNECT 1. Install the pressure switch assembly making sure all O-rings are in place. 2. Torque the 6 bolts holding the pressure switch assembly to 12 N.m (9 lb. ft.). 3. Install the transaxle case side cover. Refer to "Case Side Cover". 4. Connect the negative battery cable. 5. Refill transaxle with fluid to proper level. See "Oil Level Checking and Fill procedure". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: Customer Interest A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7218 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7219 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7225 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 7226 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations LH Side Of Engine Compartment LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 7238 LH Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7239 Transaxle Range Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7240 Transmission Position Switch/Sensor: Testing and Inspection Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 7241 Diagnostic Chart Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 3T40 Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT 1. Tool J 41545 Important - After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 7244 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 7245 Transmission Position Switch/Sensor: Service and Repair 4T40-E Automatic Transmission REMOVE OR DISCONNECT 1. Negative battery cable. 2. Shift linkage. 3. Electrical connector. 4. Mounting bolts. 5. Switch assembly. Replacement - Using Old Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral." 2. Align flats of shift shaft with switch. 3. Mounting bolts, loosely. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 3T40 Automatic Transmission > Page 7246 1. Tool J 41545 Important After switch adjustment, verify that engine will only start in "Park" or "Neutral". If engine will start in any other position, re-adjust switch. Replacement - Using New Switch INSTALL OR CONNECT 1. Place shift shaft in "Neutral". 2. Align flats of shift shaft to flats in switch and install switch assembly. 3. Mounting bolts. 4. Insert tool J 41545 and rotate switch until tool drops into position. Tighten Bolts to 24 N.m (18 lb ft). Important After switch installation verify that engine will only start in "Park" or "Neutral." If engine will start in any other position, readjust switch using "Replacement - Using Old Switch" procedure. Adjust 1. Place transaxle control shifter assembly in the "Neutral" notch in detent plate. 2. Loosen switch attaching bolts. 3. Rotate switch on shifter assembly to align service tool J 41545. Tighten Bolts to 24 N.m (18 lb ft). 4. Remove tool J 41545 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation LAMP ILLUMINATION When the Electronic Brake Control Module (EBCM) needs to illuminate the ABS indicator lamp, it will transmit a signal (via serial data link) to the Electronic Instrument Panel Cluster (IPC) and the IPC will illuminate the indicator lamp. The Amber ABS Indicator Lamp - will be illuminated to alert the driver of a malfunction. This indicates that the malfunction affects operation of the ABS. Normal (non-antilock) braking will remain. In order to regain ABS braking ability, the ABS must be serviced. As a bulb check procedure, the EBCM will command the ABS indicator lamp ON for 3 seconds when the EBCM receives power (ignition in RUN or START positions). With the ignition in the OFF/UNLOCK position (loss of serial data), the IPC will illuminate the ABS indicator lamp. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Lamp Test ABS Light: Testing and Inspection Lamp Test This test allows the user to control all the warning/indicator lamps associated with the IPC. It can be used to check the lamp circuits and the serial data link to the IPC. When using this test, all the indicators associated with the IPC will be ON. This test is similar to a BULB CHECK. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Lamp Test > Page 7254 ABS Light: Testing and Inspection Symptom Diagnosis ABS Warning Lamp Always ON, No DTC's Stored Table A : ABS Warning Indicator On With No DTCs Set ABS/ETS Circuit Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Lamp Test > Page 7255 CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the Electronic Brake Control Module (EBCM) and the Instrument Panel Cluster (IPC). A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wiring connections or physical damage to the wiring harness. ABS Warning Indicator Inoperative Table B ABS Warning Indicator Inoperative Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Lamp Test > Page 7256 ABS/ETS Circuit Schematic CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wiring connections or physical damage to the wiring harness. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations > Page 7260 Electronic Brake Control Relay: Description and Operation The Electronic Brake Control Relay is a normally-open contact type, and has special contact material to handle the high currents required for ABS VI operation. The relay allows the battery voltage and current to be supplied to the EBCM, which supplies power to the motors and solenoids. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations > Page 7261 Electronic Brake Control Relay: Service and Repair REMOVE OR DISCONNECT 1. Nut attaching Electronic Brake Control Relay. 2. Electronic Brake Control Relay. INSTALL OR CONNECT 1. Electronic Brake Control Relay. 2. Nut attaching Electronic Brake Control Relay. Tighten nut to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7270 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7271 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7277 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7278 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > EBCM EBCM Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > EBCM > Page 7281 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 Electronic Brake Control Module: Diagrams C1 Electronic Brake Control Module (EBCM): C1 Electronic Brake Control Module (EBCM)l: C1 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 7284 Electronic Brake Control Module: Diagrams C2 Electronic Brake Control Module (EBCM)l: C2 Electronic Brake Control Module (EBCM)l: C2 (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 7285 Electronic Brake Control Module (EBCM)l: C2 (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 7286 Electronic Brake Control Module: Description and Operation CONTROLS, INPUTS AND OUTPUTS The controlling element of ABS VI is a microprocessor based Electronic Brake Control Module (EBCM). Inputs to the system include four wheel speed sensors, the brake switch, the brake fluid level switch, ignition switch, and unswitched battery voltage. Outputs include three bi-directional motor controls, two solenoid controls and the Electronic Brake Control Relay. A serial data line is used for service diagnostic tools (Scan Tool), assembly plant testing and control of indicator lamps in the IPC. OPERATION The EBCM monitors the speed of each wheel. If any wheel begins to approach lock-up, the EBCM controls the motors and solenoids to reduce brake pressure to the wheel approaching lock-up. Once the wheel regains traction, brake pressure is increased until the wheel again begins to approach lock-up. This cycle repeats until either the vehicle comes to a stop, the brake is released, or no wheels approach lock-up. With ETS, the EBCM monitors the wheel spin slip through the front wheel speed sensors. If either of the front wheels begins to slip, the EBCM determines the desired wheel torque needed to minimize front wheel spin. This information is sent to the Powertrain Control Module (PCM) via the serial data link. The PCM then calculates a spark retard value to achieve the requested torque and upshifts the transmission if needed. DIAGNOSTICS The EBCM monitors itself, each input and each output for proper operation. If any system malfunction is detected, the EBCM will store a DTC in nonvolatile memory (DTCs will not disappear if the battery is disconnected). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 7287 Electronic Brake Control Module: Service and Repair EBCM Removal REMOVE OR DISCONNECT 1. Dash wiring harness connectors from EBCM. 2. EBCM from bracket. INSTALL OR CONNECT 1. EBCM to bracket 2. Dash wiring harness connectors to EBCM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 7292 LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly, Traction Control > Component Information > Locations > Page 7293 Hydraulic Assembly: Diagrams LH Rear Engine Compartment-Front Of Dash ABS Actuator Motor Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7302 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7303 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7309 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7310 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > General Description Traction Control Indicator Lamp: Description and Operation General Description CONDITIONS When the Electronic Brake Control Module (EBCM) needs to illuminate the "ETS OFF" or "LO TRAC" indicator lamps, it will transmit a signal (via serial data link) to the electronic Instrument Panel Cluster (IPC) and the IPC will illuminate the indicator lamp. The Amber "ETS OFF" Indicator Lamp - will be illuminated when ETS is disabled or when the driver switches ETS off with the ETS switch. As a bulb check procedure, the EBCM will command the ETS indicator lamp ON for 3 seconds when the EBCM receives power (ignition in RUN position). With the ignition in the OFF/UNLOCK or START positions (loss of serial data), the IPC will illuminate the ETS OFF indicator lamp. The Amber "LO TRAC" Indicator Lamp - will be illuminated to alert the driver of a low traction situation and to inform the driver the ETS is operating. As a bulb check procedure, the EBCM will command the LO TRAC indicator lamp ON for 3 seconds when the EBCM receives power (ignition in RUN or START positions). With the ignition in the OFF/UNLOCK position (loss of serial data), the IPC will illuminate the LO TRAC indicator lamp. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > General Description > Page 7315 Traction Control Indicator Lamp: Description and Operation Circuit Description Low Trac Indicator LOW TRAC (Option With 4 Speed Automatic Transaxle Only) The LOW TRAC Indicator is controlled by the IPC as commanded by the EBCM via serial data. The EBCM will command this indicator "ON" when the Enhanced Traction System is engaged. The EBCM will also command this telltale "ON" for three seconds when it is powered up (ignition in "RUN") as a bulb check procedure. During a loss of EBCM serial data communication (ignition m OFF/UNLOCK" or "CRANK"), the telltale will also he illuminated. Enhanced Traction System Telltale ETS OFF (Option With 4 Speed Automatic Transaxle Only) The Enhanced Traction System telltale is controlled by the IPC as commanded by the EBCM via serial data. This telltale will light when either the ETS is turned off or the ETS is unavailable due to a problem with the Anti-lock Brake System. The EBCM will command this telltale "ON" for three seconds when it is powered up (ignition m RUN") as a bulb check procedure. During a loss of EBCM serial data communication (ignition in "OFF/UNLOCK" or "CRANK"), the telltale will also be illuminated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set Traction Control Indicator Lamp: Testing and Inspection ETS Off Indicator ON With No DTCS Set Table-C - ETS Off, Indicator Lamp On With No DTCs Set ABS/ETS Circuit Schematic CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 7318 terminal to wiring connections or physical damage to the wiring harness. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 7319 Traction Control Indicator Lamp: Testing and Inspection ETS Off Warning Indicator Inoperative Table D ETS Off Warning Indicator Inoperative ABS/ETS Circuit Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 7320 CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wiring connections or physical damage to the wiring harness. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations Center Passenger Compartment, Above Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations > Page 7325 LH I/P And Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set Wheel Speed Sensor: Customer Interest ABS Indicator Lamp On, DTC 21,22,32 or 33 Set File In Section: 5 - Brakes Bulletin No.: 63-50-15B Date: March, 1998 Subject: ABS Indicator Lamp ON, DTC 21, 22, 32 or 33 Set (Install Front ABS Wheel Speed Sensor Wiring Harness Connector Kit) Models: 1992-97 Buick Skylark 1991-96 Chevrolet Beretta, Corsica 1992-97 Chevrolet Cavalier 1992-97 Oldsmobile Achieva 1992-94 Pontiac Sunbird 1995-97 Pontiac Sunfire 1992-97 Pontiac Grand Am This bulletin is being revised to update parts and applicable model information. Please discard Corporate Bulletin Number 63-50-15A - (Section 5 - Brakes) Condition Some owners may comment that the ABS indicator lamp is "ON". Also, malfunction DTC 21, 22, 32 or 33 could set. Cause The right front and left front ABS wheel speed sensor wiring harness could be damaged and result in an open circuit. The wiring harness may be damaged approximately 4 inches (10 cm) back from the harness connector to the wheel speed sensor. This allows moisture to enter the harness causing corrosion and resulting in the open circuit. Correction A thorough inspection for corrosion and/or damage should be performed on suspect vehicles. It may be necessary to move the protective conduit away in order to inspect the wiring properly. If a failure occurs and damage is found, install the front ABS wheel speed sensor wiring harness connector kit(s). The kit includes instructions, splices, and "pigtail" connector. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set > Page 7334 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time H2530 Right Side Use published H2531 Left Side Labor Operation Time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set Wheel Speed Sensor: All Technical Service Bulletins ABS Indicator Lamp On, DTC 21,22,32 or 33 Set File In Section: 5 - Brakes Bulletin No.: 63-50-15B Date: March, 1998 Subject: ABS Indicator Lamp ON, DTC 21, 22, 32 or 33 Set (Install Front ABS Wheel Speed Sensor Wiring Harness Connector Kit) Models: 1992-97 Buick Skylark 1991-96 Chevrolet Beretta, Corsica 1992-97 Chevrolet Cavalier 1992-97 Oldsmobile Achieva 1992-94 Pontiac Sunbird 1995-97 Pontiac Sunfire 1992-97 Pontiac Grand Am This bulletin is being revised to update parts and applicable model information. Please discard Corporate Bulletin Number 63-50-15A - (Section 5 - Brakes) Condition Some owners may comment that the ABS indicator lamp is "ON". Also, malfunction DTC 21, 22, 32 or 33 could set. Cause The right front and left front ABS wheel speed sensor wiring harness could be damaged and result in an open circuit. The wiring harness may be damaged approximately 4 inches (10 cm) back from the harness connector to the wheel speed sensor. This allows moisture to enter the harness causing corrosion and resulting in the open circuit. Correction A thorough inspection for corrosion and/or damage should be performed on suspect vehicles. It may be necessary to move the protective conduit away in order to inspect the wiring properly. If a failure occurs and damage is found, install the front ABS wheel speed sensor wiring harness connector kit(s). The kit includes instructions, splices, and "pigtail" connector. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set > Page 7340 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time H2530 Right Side Use published H2531 Left Side Labor Operation Time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure Engine Oil Pressure: All Technical Service Bulletins Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure File In Section: 6 Engine Bulletin No.: 77-61-09B Date: October, 1997 Subject: Engine Stall at Cold Start, Rough Idle, Oil Filter Expansion, High Oil Pressure, and P0300 DTCs (Replace Oil Pump Cover Assembly) Models: 1995-97 Buick Skylark 1995-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1995-97 Oldsmobile Achieva 1995-97 Pontiac Sunfire, Grand Am with 2.3L, 2.4L Engine (VINs D, T - RPOs LD2, LD9) This bulletin is being revised to add a new Service Procedure and to revise the Service Parts ln1ormation. Please discard Corporate Bulletin Number 77-61-09A (Section 6 - Engine). Condition Some vehicles may exhibit one of a number of concerns related to this condition. The most common symptom will be stalling on initial cold starting, followed by hard restarting. Other concerns may include oil filter canister expansion or leakage and high oil pressure when checked with a gauge. Some vehicles may also exhibit Diagnostic Trouble Codes P0300, P0301, P0302, P0303, and P0304 indicating engine misfire conditions. Oil pressure at operating temperature may exceed 827 kPa (120 psi). Cause Due to a condition of the relief valve and the relief valve bore, the relief valve may intermittently become stuck causing high oil pressure. The increased oil pressure may cause the hydraulic valve lifters to raise the valves off of their seats creating a loss of compression and engine misfire or stalling on initial start-up. Diagnosis If the vehicle exhibits any of the above conditions, install an oil pressure gauge calibrated to read at least 1034 kPa (150 psi) in the oil pressure port on the intake camshaft carrier and observe oil pressure at 3000 RPM. The oil pressure, even in extreme cold, should not exceed 689 kPa (100 psi). With the engine oil at operating temperature, oil pressure should not exceed 586 kPa (85 psi) at 3000 RPM. Correction If the oil pressure exceeds these limits, replace the Oil Pump Cover with an oil pump cover that has an improved pressure relief valve and pressure relief valve bore. Service Procedure 1. Remove the Radiator Outlet Pipe and the Engine Oil Pan, using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. 2. Remove the Balance Shaft Drive Chain cover. 3. Remove the Balance Shaft Drive Chain Tensioner shoe. Important: DO NOT remove the balance shaft drive chain or Balance Shaft Drive Sprocket. 4. Remove only the Oil Pump cover assembly. 5. Install the new Oil Pump Cover Assembly GM P/N 24577081. 6. Tighten the four long bolts to 12 N.m (106 lb in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 7346 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 77-61-09B > Oct > 97 > Engine - Rough Idle/Miss/Cold Stall/High Oil Pressure > Page 7352 7. Tighten the short bolt to 10 N.m (89 lb in.). 8. Install the Balance Shaft Drive Chain Tensioner Shoe and the Balance Shaft Drive Chain Cover using procedures outlined in Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Important: Do not use excessive pressure when installing the Balance Shaft Drive Chain Tensioner. Excessive Balance Shaft Drive Chain tension will result in noise and wear concerns. 9. Reinstall the Engine Oil Pan and the Radiator Outlet pipe, Refer to Section 6A7 or the Engine Mechanical Section of the appropriate Service Manual. Parts Information Whenever ordering parts, refer to the following part number: GM Part Number Description 24577081 Cover Assembly, Engine Oil Pump Warranty Information For vehicles repaired under warranty, use one of the applicable warranty labor operation numbers as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 7353 Wheel Speed Sensor: Specifications Front Wheel Sensor Bolt 107 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead LH Front Wheel (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7356 LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7357 Front Wheel Speed Sensor Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7358 LH Front Wheel (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7359 Rear Axle Harness Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service Precautions > Technician Safety Information Wheel Speed Sensor: Technician Safety Information WARNING: Raise and support vehicle on suitable hoist . Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service Precautions > Technician Safety Information > Page 7362 Wheel Speed Sensor: Vehicle Damage Warnings CAUTION: ^ The front wheel speed sensor wiring is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. ^ The front wheel speed sensor wiring is not repairable in the control arm section of the wiring harness. This section of the wiring harness must be replaced with the appropriate wiring harness service kit "pigtail." The splice must be located within the main branch of the engine harness. Do not attempt to solder, splice, or crimp this section of the wiring harnesses as eventual failure will likely result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring Wheel Speed Sensor: Description and Operation Toothed Ring The toothed ring mentioned above is pressed onto the outer Constant Velocity (CV) joint. Each ring contains 48 equally spaced teeth. Care should be exercised during service procedures to avoid contact with this ring, as damage to one or more teeth may result. If the ring is damaged, the outer CV joint must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7365 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensors The front wheel speed sensors are of a variable reluctance type. Each sensor is attached to the knuckle assembly in close proximity to a toothed ring. An AC voltage is generated when the toothed ring passes by the sensor. The magnitude and frequency are proportional to the speed of the wheel and both will increase with increasing speed. The sensor is not repairable, nor is the air gap adjustable. However, air gap should be between 0.5 mm (0.020 inches) and 1.7 mm (0.070 inches). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7366 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Wiring The front wheel speed sensor wiring is constructed of highly flexible twisted pair wiring. This wiring exists because the front wheel speed sensor wiring circuits must connect to the suspension of the vehicle, thus the wiring in this area is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. For this reason, THE FRONT WHEEL SPEED SENSOR WIRING IS NOT REPAIRABLE IN THE CONTROL ARM SECTION OF THE WIRING HARNESS. THIS SECTION OF THE WIRING HARNESS MUST BE REPLACED WITH THE APPROPRIATE WIRING HARNESS SERVICE KIT "PIGTAIL." DO NOT ATTEMPT TO SOLDER, SPLICE, OR CRIMP THIS SECTION OF THE WIRING HARNESSES AS EVENTUAL FAILURE WILL LIKELY RESULT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7367 Wheel Speed Sensor: Description and Operation Rear Wheel Speed Sensors and Rings The rear wheel speed sensors operate in the same manner as the front wheel speed sensors. Refer to Front Wheel Speed Sensors. The wheel speed sensor and toothed ring are contained within the dust cap of the integral rear wheel bearing. This allows for improved environmental protection and easier assembly. The sensor and toothed ring are not repairable and no provision for air gap adjustment exists. If a rear wheel speed sensor fails, the entire integral bearing and speed sensor assembly must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7368 Wheel Speed Sensor: Description and Operation Rear Axle Harness The rear axle harness is constructed of twisted pair wiring. Because the rear axle harness is not subjected to the same motion as the front wheel speed sensor wiring, the rear axle harness can be serviced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Front Wheel Speed Sensor Removal REMOVE OR DISCONNECT 1. Raise and support vehicle on suitable hoist. 2. Front sensor electrical connector. 3. Retaining bolt. 4. Front wheel speed sensor. If sensor will not slide out of knuckle, remove brake rotor and use a blunt punch or equivalent tool to push sensor from back side of knuckle. If sensor locating pin breaks off and remains in knuckle during removal, proceed as follows. a. Remove brake rotor and remove broken pin using a blunt punch. b. Clean hole using sand paper wrapped around a screwdriver or other suitable tool. Never attempt to enlarge the hole. INSTALL OR CONNECT 1. Front wheel speed sensor on mounting bracket. Make sure front wheel speed sensor is properly aligned and lays flat against bosses on knuckle. 2. Retaining bolt. Tighten retaining bolt to 12 Nm (107 inch lbs.). 3. Front sensor electrical connector to front wheel speed sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7371 Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Wiring Right Front Wheel Speed Sensor Harness Left Front Wheel Speed Sensor Harness CAUTION: ^ The front wheel speed sensor wiring is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. ^ The front wheel speed sensor wiring is not repairable in the control arm section of the wiring harness. This section of the wiring harness must be replaced with the appropriate wiring harness service kit "pigtail." The splice must be located within the main branch of the engine harness. Do not attempt to solder, splice, or crimp this section of the wiring harnesses as eventual failure will likely result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7372 REMOVE OR DISCONNECT 1. Connector from wheel speed sensor. 2. Harness attaching clips for control arm and splash shield. 3. Lower vehicle. 4. Harness attaching clips from strut tower. 5. Cut wheel speed sensor wiring circuits within main engine harness. 6. Strip insulation on engine harness leads and new wheel speed sensor harness leads. INSTALL OR CONNECT 1. Splice sleeve provided in jumper harness kit over each engine harness leads. 2. New wheel speed sensor harness leads to engine harness leads (matching color) and crimp connections. 3. Heat shrink tube lightly to seal. 4. Harness attaching clip to strut tower. 5. Raise and support vehicle on suitable hoist. 6. Harness attaching clips to control arm and splash shield. 7. Connector to wheel speed sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7373 Wheel Speed Sensor: Service and Repair Rear Axle Harness Rear Axle Harness Removal WARNING: Raise and support vehicle on suitable hoist. REMOVE OR DISCONNECT 1. Two rear sensor electrical connectors from rear wheel bearing and speed sensor assemblies. 2. Rear axle harness electrical connector from body to ABS and fuel sender connector. 3. Wire harness from restraints. 4. Rear speed sensor wiring harness from vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7374 INSTALL OR CONNECT 1. Rear speed sensor wiring harness in vehicle. 2. Wire harness restraints. 3. Rear ABS axle harness electrical connector to body to ABS and fuel sender connector. 4. Two rear sensor electrical connectors to rear wheel bearing and speed sensor assemblies. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System Brake Bleeding: Service and Repair Bleeding Brake Hydraulic System Scan Tool Method 1. Using a scan tool, select MOTOR REHOME. The motor rehome function cannot be performed if current DTCs are present. If DTCs are present, the vehicle must be repaired and DTCs cleared before performing the motor rehome function. 2. The entire brake system can now be bled. Without Scan Tool NOTE: This method can only be used if the ABS indicator lamp is not illuminated and no DTCs are present. Do not place your foot on the brake pedal through this entire procedure unless specifically directed to do so. 1. Remove foot from brake pedal. 2. Start engine and allow it to run for at least 10 seconds while observing the ABS indicator lamp. 3. If the ABS indicator lamp turned ON and stayed ON after about 10 seconds, a scan tool must be used to diagnose the ABS malfunction. 4. If the ABS indicator lamp turned ON for approximately 3 seconds, then turned OFF and stayed OFF, turn the ignition OFF. 5. Repeat Steps 1 through 4 one more time. 6. The entire brake system can now be bled. General Information WARNING: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. REMOVING AIR FROM THE SYSTEM A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the brake system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipe at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If pipes are disconnected at any fitting located between master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. The time required to bleed the hydraulic system can be reduced if the master cylinder reservoir is filled with brake fluid and as much air as possible is expelled before the master cylinder is installed on the vehicle. Pressure Bleeding Master Cylinder Pressure Bleeding Adapter NOTE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system. 1. Install J 35589 to the master cylinder. 2. Charge J 29532 to 140-172 kPa (20-25 psi). 3. Connect line to J 35589 and open line valve. 4. Raise vehicle and suitably support. 5. If it is necessary to bleed all of the calipers/cylinders, the following sequence should be followed: Right rear Left rear Right front Left front 6. Place a proper size box end wrench (or J 21472) over the caliper/cylinder bleeder valve. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System > Page 7379 7. Attach a clear tube over the bleeder screw. Submerge the other end of the tube in a clear container partially filled with clean brake fluid. 8. Open the bleeder screw at least 3/4 of a turn and allow flow to continue until no air is seen in the fluid. 9. Close the bleeder screw.Tighten Rear bleeder screws to 7 Nm (62 inch lbs.) and Front bleeder screws to 13 Nm (115 inch lbs.) 10. Repeat Steps 6 through 9 until all calipers/cylinders have been bled. 11. Lower vehicle. 12. Check the brake pedal for "sponginess." Repeat entire bleeding procedure to correct either of these two conditions. 13. Remove J 35589 and J 29532. 14. Fill the master cylinder to the proper level. Manual Bleeding Deplete the vacuum reserve by applying, the brakes several times with the ignition "Off". Use extreme care to prevent brake fluid from contacting painted surfaces. 1. Fill the master cylinder reservoir with brake fluid. Maintain the fluid level in the reservoir during the bleeding operation. It is necessary to have an assistant in the vehicle to press on the brake pedal during the manual bleeding procedure. 2. If the master cylinder is known or suspected to have air in the bore, then it must be bled before any wheel cylinder or caliper in the following manner: a. Disconnect the front brake pipe connection(s) at the master cylinder. b. Allow brake fluid to fill the master cylinder until it begins to flow from the front pipe connector port. c. Connect the forward brake pipe(s) to the master cylinder and tighten. d. Depress the brake pedal slowly one time and hold. Loosen the front brake pipe connection at the master cylinder to purge air from the bore. Tighten the connection and then release the brake pedal slowly. Wait 15 seconds. Repeat the sequence, including the 15 second wait, until all air is removed from the bore. Care must be taken to prevent brake fluid from contacting any painted surface. After all air has been removed at the forward connection(s), bleed the master cylinder at the rear (cowl) connection(s) in the same manner as the front. e. If it is known that the calipers and wheel cylinders do not contain any air, then it will not be necessary to bleed them. 3. Individual wheel cylinder or calipers are bled only after all air is removed from the master cylinder. 4. If is necessary to bleed all of the wheel circuits, the following sequence should be followed: 1st - Right rear / 2nd - Left rear / 3rd - Right front / 4th - Left front 5. Raise vehicle.. 6. Place a proper size box end wrench (or special tool) over the caliper/cylinder bleeder valve. 7. Attach a clear tube over the bleeder screw. Submerge the other end of the tube in a clear container partially filled with clean brake fluid. 8. Depress the brake pedal slowly one time and hold. Loosen the bleeder screw to purge air from the cylinder/caliper. Tighten bleeder screw and slowly release pedal. Wait 15 seconds. Repeat the sequence, including the 15 second wait, until all air is removed. It may be necessary to repeat the sequence 10 or more times to remove all the air. Rapid pumping of the brake pedal pushes the master cylinder secondary piston down the bore in a way that makes it difficult to bleed the system. Tighten rear bleeder screws to 7 Nm (62 inch lbs.) and front bleeder screws to 13 Nm (115 inch lbs.) 9. Lower vehicle. 10. Fill the master cylinder to the proper level. 11. Check the brake pedal for "sponginess" or excessive travel. Repeat entire bleeding procedure to correct either of these two conditions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System > Page 7380 Brake Bleeding: Service and Repair Flushing Brake Hydraulic System The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contains the slightest trace of petroleum or mineral based fluids. All rubber parts, including the brake hoses, that have been exposed to contaminated fluid must be replaced. Approximately one quart of fluid is required to flush the hydraulic system. When flushing the system use the steps specified in pressure bleeding procedures shown in "Bleeding Brake Hydraulic System." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications FASTENER TIGHTENING SPECIFICATIONS Brake Pedal to Bracket ........................................................................................................................ ........................................... 27 Nm (20 ft. lbs.) Booster to Pedal Bracket ........................................... ..................................................................................................................... 27 Nm (20 ft. lbs.) DEMENSIONS Brake Pedal Travel .............................................................................................................................. ....................................... 63.5 mm (2.5 inches) NOTE: Brake pedal travel maximum with 445 N (100 lb) force applied to pedal with ignition "OFF" and vacuum assist depleted. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Locations > Brake Pedal LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Locations > Brake Pedal > Page 7386 LH Lower I/P Near Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Locations > Page 7387 Brake Pedal Assy: Testing and Inspection 1. With engine off and key "Off", pump service brake pedal until all reserve is exhausted from the brake booster. 2. Install J 28662 or equivalent onto the brake pedal. 3. Hook end of tape measure over top edge of brake pedal and measure the distance to the rim of the steering wheel. 4. Apply service brake pedal with a firm force (approximately 445 N (100 lbs) and re-measure. The difference between both readings is the actual pedal travel and should not exceed 63 mm (2.5 inches). 5. If pedal travel is greater than 63 mm (2.5 inches) drive the vehicle backward while intermittently applying the brakes. In rare cases excessive pedal travel will develop if brakes are only used occasionally when backing up. Duo-Servo self-adjusting mechanisms will only actuate when the brakes are applied in reverse. If clearance is not to specification it may be necessary to manually adjust brake shoe to drum clearance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Locations > Page 7388 Brake Pedal Assy: Service and Repair Brake Pedal Assembly Mounting REMOVE OR DISCONNECT 1. Left sound insulator panel. 2. Push rod from brake pedal. 3. Accelerator cable. 4. Brake pedal assembly. 5. Electrical connections. INSTALL OR CONNECT 1. Electrical connections. 2. Brake pedal assembly. 3. Accelerator cable. 4. Pushrod to brake pedal. 5. Left sound insulator panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 Brake Warning Indicator: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7419 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7420 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7421 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 Brake Warning Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Antilock Brake System Brake Warning Indicator: Description and Operation Antilock Brake System The antilock brake system uses two indicator lamps, a red "BRAKE" warning lamp and an amber "ANTLOCK" lamp, both located in the instrument panel cluster. Under normal conditions, these lamps should activate as follows: 1. When ignition is turned to the "RUN" position, p~rior to starting the engine, the amber 'ANTILOCK" lamp should turn "ON". 2. As the engine is cranked, the red "BRAKE" lamp and the amber "ANTILOCK" lamp should come 3. When the engine is started, both lamps should be "OFF". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Antilock Brake System > Page 7427 Brake Warning Indicator: Description and Operation Standard Brake System The BRAKE Indicator lamp has two functions. First, it will light whenever the park brake is set. Second, a switch built into the brake master cylinder reservoir will signal the EBCM if the brake fluid level drops below a safe level. The EBCM will command the indicator "ON" via serial data with the IPC. In addition, the indicator is commanded "ON" when the EBCM is initially powered up (ignition m RUN" position). With the ignition in the "OFF/UNLOCK" or "CRANK" positions (loss of EBCM serial data), the telltale will also be illuminated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Mounting Bolt and Sleeve Assembly 38 ft.lb Caliper Inlet Fitting 34 ft.lb Caliper Bleeder Valve 115 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Technician Safety Information Brake Caliper: Technician Safety Information CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, or by cleaning brake parts with a dry brush or with compressed air. Many brake parts contain asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment is commercially available to perform this washing function. These wet methods will prevent asbestos fibers from becoming airborne. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Technician Safety Information > Page 7434 Brake Caliper: Vehicle Damage Warnings NOTE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener tightening specification and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Page 7435 Brake Caliper: Description and Operation This caliper has a single bore and is mounted to the steering knuckle with two mounting bolts. Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the caliper piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward resulting in a clamping action on the rotor. This clamping action forces the linings against the rotor, creating friction to stop the vehicle. NOTE: Install all new components included in the repair kit used to service this caliper. Lubricate rubber parts with clean brake fluid to ease assembly. Do not use lubricated compressed air on brake parts as damage to rubber components may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. Replace shoe and linings in axle sets only. The tightening specifications are for dry, unlubricated fasteners. Perform service operations on a clean bench, free from all mineral oil materials. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Replacement Brake Caliper: Service and Repair Caliper Replacement NOTE: Install all new components included in the repair kit used to service this caliper. Lubricate rubber parts with clean brake fluid to ease assembly. Do not use lubricated compressed air on brake parts as damage to rubber components may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. Replace shoe and linings in axle sets only. The tightening specifications are for dry, unlubricated fasteners. Perform service operations on a clean bench, free from all mineral oil materials. Disc Brake Caliper Assembly REMOVE OR DISCONNECT 1. Remove 2/3 of brake fluid from master cylinder assembly. 2. Raise vehicle and suitably support. Mark relationship of wheel to hub and bearing assembly, to insure proper wheel balance upon reassembly. 3. Tire and wheel assembly. Reinstall two wheel nuts to retain rotor to hub and bearing assembly. Compressing Piston 4. Push piston into caliper bore to provide clearance between linings and rotor. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe. Slowly tighten C-clamp until piston is pushed into the caliper bore enough to slide the caliper assembly off rotor. 5. Bolt attaching inlet fitting only when caliper is to be removed from vehicle for unit repair (overhaul). If only shoe and linings are being replaced, there is no need to disconnect inlet fitting. Plug exposed inlet fitting in caliper housing and brake hose to prevent fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7438 Caliper Mounting 6. Caliper mounting bolts and sleeve assemblies. Suspending Caliper 7. Caliper from rotor and knuckle. Do not let caliper hang from brake hose. Damage may occur. If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut. Inspect mounting bolts and sleeve assemblies for corrosion. Bushings for cuts or nicks. If damage to either part is found, replace with new parts when installing caliper. Do not attempt to polish away corrosion. INSTALL OR CONNECT Lubricating Caliper Cavity 1. Liberally coat inside diameter of bushings with silicone grease. 2. Mounting bolts and sleeve assemblies. 3. Caliper over rotor into knuckle. Tighten mounting bolt and sleeve assemblies to 51 Nm (38 ft. lbs.). 4. Inlet fitting, if removed. Tighten inlet fitting to 44 Nm (32 ft. lbs.). 5. Wheel and tire, aligning previous marks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7439 a. Remove wheel nuts securing rotor to hub and bearing assembly. b. Install wheel and tire assembly with retaining nuts in proper sequence. c. Lower the vehicle. d. Torque wheel nuts. 6. Fill master cylinder to proper level with clean brake fluid. Bleed caliper if inlet fitting was removed. Recheck fluid level. Recheck brake pedal feel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7440 Brake Caliper: Service and Repair Caliper Overhaul Caliper Assembly DISASSEMBLE 1. Remove caliper completely from vehicle. See: Caliper Replacement 2. Bushings. Inspect bushings for cuts and nicks. Replace if damaged. Use clean shop towels to pad the interior of the caliper housing during removal. WARNING: On the following procedure do not place fingers in front of the piston in an attempt to catch or protect it when applying compressed air. This could result in serious injury. Removing Caliper Piston 3. Piston using compressed air into the caliper inlet hole. Inspect piston for scoring, nicks, corrosion and worn or damaged chrome plating. Replace piston if any of these conditions are found. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7441 Removing Boot 4. Boot from caliper housing bore. Be careful not to scratch housing bore. 5. Piston seal from seal groove in caliper housing bore with a small wood or plastic tool.Inspect caliper housing bore and seal groove for scoring, nicks, corrosion and wear. Use crocus cloth to polish out light corrosion. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth. CAUTION: Do not use a metal tool since this may damage caliper bore or seal groove. 6. Bleeder valve and bleeder valve cap from caliper. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. Blow out all passages in caliper housing and bleeder valve. ASSEMBLE 1. Bleeder valve and bleeder valve cap into caliper. Tighten bleeder valve to 13 Nm (115 inch lbs.). 2. Lubricate new piston seal and install into caliper bore groove. Make sure seal is not twisted. Installing Boot Onto Piston 3. Lubricated boot onto piston. 4. Piston and boot into bore of caliper and push to bottom of bore. Seating Boot Into Caliper Housing 5. Seat boot in caliper housing counter bore using J 29077-A. 6. Bushings. Lubricate beveled end of bushing with silicone grease. Pinch bushing and install bevel end first. Push bushing through housing mounting bore. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7442 7. Caliper. See: Caliper Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 7443 Brake Caliper: Tools and Equipment Special Tools Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum Thickness Minimum Thickness Wear Limit 0.030 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 7447 Brake Pad: Testing and Inspection Inspect the brake linings every 9654 km (6,000 miles) and any time that the tire and wheel assembly is removed (tire rotation, etc.). Check both ends of the outer pad by looking in at each end of the caliper. These are the points at which the highest rate of wear normally occurs. However, at the same time, check the lining thickness on the inner shoe to make sure that it has not worn prematurely. Some inboard shoe and linings have a thermal layer against the shoe which is integrally molded with the lining. This extra layer should not be confused with uneven inboard-outboard lining wear. Look down through the inspection hole in the top of the caliper to view the inner shoe. Replace disc brake shoe and lining assemblies whenever the thickness of any lining is worn to within 0.76 mm (0.030 inches) of the shoe. In the case of riveted shoe and lining assemblies, replace when the lining is worn to within 0.76 mm (0.030 inches) of any rivet head. Replace all disc brake shoe and lining assemblies at the same time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 7448 Brake Pad: Service and Repair Shoe And Lining Assembly REMOVE OR DISCONNECT 1. Caliper. Remove Outboard Shoe And Lining 2. Outboard shoe and lining. Use screwdriver to disengage buttons on shoe from holes in caliper housing. 3. Inboard shoe and lining. NOTE: Before installing new shoe and linings, use denatured alcohol to wipe outside surface of boot clean. INSTALL OR CONNECT 1. Bottom piston into caliper bore. Use a C-clamp over caliper housing to drive piston in. Tighten clamp slowly to drive piston into caliper bore. Take care not to damage piston or piston boot with C-clamp. After bottoming piston, lift inner edge of boot next to piston and press out any trapped air. Boot must lay flat. Make sure convolutions are tucked back into place. Installing Inboard Shoe And Lining Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 7449 2. Inboard shoe and lining by snapping shoe retaining spring into piston inside diameter. Shoe retainer spring is already staked to the inboard shoe. Shoe must lay flat against piston. After installing shoe and lining, check that boot is not touching the shoe. If there is contact, remove the shoe and lining and re-seat or re-position the boot. Installing Outboard Shoe And Lining 3. Outboard shoe and lining with wear sensor at trailing edge of shoe. During forward wheel rotation, the back of the shoe must lay flat against caliper. 4. Caliper. 5. Apply a firm force three times to the brake pedal to seat the linings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information Bulletin No.: 01-05-23-001B Date: January 31, 2008 INFORMATION Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction Models: 2008 and Prior Passenger Cars Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-05-23-001A (Section 05 - Brakes). This bulletin is being issued to update General Motors position on correcting brake rotor lateral runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service procedures). Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation, such as ABS pedal feedback, have been addressed before checking rotor runout. Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or to refinish the rotor using an on-vehicle brake lathe. GM has approved a new technology for the correction of lateral runout on new or refinished rotors. This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in) or less requirement for lateral runout by installing a specially selected, tapered correction plate between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of an on-vehicle brake lathe to correct for lateral runout. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various correction sizes, that will cover most current GM passenger car applications. It will also include a Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful tools. Service Procedure Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction procedure: The existing rotors must first be machined on an approved, well-maintained bench lathe to guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note that it is not necessary to machine new rotors. Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining washers provided in the kit. Do not reinstall the caliper or wheel at this time. Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the equivalent. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge. Rotate the rotor and observe the total lateral runout. Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is .050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be reassembled. If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake Align(R) Correction as follows: Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor to determine and locate the highest amount of lateral runout. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7454 Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud relative to this location. Remove the rotor. Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application Chart. Make sure the selection corrects the amount of runout that was diagnosed. Never attempt to stack two or more Correction Plates together on one hub. Never attempt to re-use a previously installed Correction Plate. Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned with the noted location of the "high spot" on the vehicle hub and marked wheel stud. Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be sure to install the rotor onto the hub in the same location as identified in Step 7. The rotor should then be secured onto the hub and tightened to the proper specification. The rotor should be dial indicated once more to assure that the rotor is now within specification. The brake system is now ready for the remaining service and assembly. Once the caliper has been installed, check to ensure that the rotor rotates freely. Parts Information Brake Align(R) Runout Correction Plates are available through the suppliers shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7455 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7456 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7457 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7458 Brake Align Order Form Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7459 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor & Hub Flange Cleaning Tool Revision File In Section: 5 - Brakes Bulletin No.: 73-50-37 Date: January, 1998 INFORMATION Subject: Revision to J 42450 Tool; Proper Brake Rotor and Hub Flange Surface Cleaning Models: 1998 and Prior Passenger Cars and Light Duty Trucks - with Disc Brakes (Rotor and Hub Separate) This bulletin is being revised to update the following text. This bulletin is being issued to inform the dealer about a revision to tool J 42450 and reinforce the need for proper hub flange and brake rotor mating surface cleaning during service. Tool J 42450 is a cleaning pad arbor and pad system that fits over the wheel stud and cleans the portion of the hub surface that is very difficult to reach with normal rotary cleaning pads. Tool J 42450 is being revised to J 42450-A to improve the hook and loop material retention. Any dealer experiencing problems with tool J 42450 should contact Kent-Moore at 1-800-345-2233 for a revised arbor at no charge. Anytime the brake rotor has been separated from the hub bearing flange or if rotor machining is necessary, the rotor and hub should be marked to maintain the original position. Clean the hub flange of all dirt and foreign material using special tool J 42450 or J 42450-A. Clean both sides of the brake rotor hub using an aggressive (80 grit) abrasive sanding pad on a rotary disc. Properly cleaning the rotor surfaces before rotor machining or reassembly ensures that dirt and corrosion will not add lateral runout to the rotor. Proper cleaning of the hub flange will also minimize the stack-up of lateral runout. On reassembly, the rotor should be reinstalled aligning the marks made on disassembly. Always use a torque wrench or the appropriate Torque Socket found in J 39544-KIT on an impact wrench when installing the wheel and tire assembly. Torque all wheel nuts using the correct sequence and torque. Refer to the Tire and Wheel Sub-Section in the applicable Service Manual. Excessive torque or torque variation between wheel nuts may cause distortion of the hub and rotor mating surface. This distortion may cause lateral runout and lead to brake pulsation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7460 Technical Service Bulletin # 23-50-05B Date: 971101 Brakes - Rotor Warranty Service Procedure File In Section: 5 - Brakes Bulletin No.: 23-50-05B Date: November, 1997 INFORMATION Subject: Brake Rotor Warranty Service Procedure Model: 1994-98 GM Passenger Cars This bulletin outlines GM's procedures for brake rotor service for all applicable GM passenger cars and supersedes Corporate Bulletin Number 23-50-05A Section 5 - Brakes). Important: Rotors should only be turned when one or more of the following rotor surface conditions exist: 1. Severe Scoring - depth in excess of 1.5 mm (0.060 in.). 2. Pulsation Concerns from: a. Thickness variation in excess of 0.025 mm (0.001 in.). b. Corrosion on rotor braking surfaces. Rotors are NOT to be resurfaced in an attempt to correct: 1. Noise/squeal. 2. Cosmetic corrosion. 3. Routine pad replacement. 4. Discoloration and/or "hard spots". Explanation of Brake Rotor Warranty Service Procedure Research and testing has determined: 1. Rotor refacing during normal pad replacement is not necessary. 2. Rotor refacing for cosmetic corrosion is unnecessary. Clean-up of braking surfaces can be accomplished by 10-15 moderate stops from 62-75 km/h (35-40 mph) with cooling time between stops. 3. Rotor service is ineffective in correcting BRAKE SQUEAL, and/or PREMATURE LINING WEAR OUT, and should NOT be used to address these conditions. 4. When installing new rotors, DO NOT reface them. 5. Ensure bearing flanges are free of corrosion when installing rotors to prevent inducing lateral runout. Use Kent Moore tool J 42450 to clean the corrosion around the wheel studs. Brake Service Techniques EVERY brake service should include: 1. Clean and lube all metal-to-metal contact points (i.e.; caliper to knuckle, pad to knuckle, etc.). 2. Clean and lube slide pins. 3. Set correct clearances - caliper to knuckle, etc. 4. Clean rotor and hub mounting surfaces. Use Kent Moore tool J 42450 to clean around wheel studs. Pulsation Brake pulsation concerns may result from two basic conditions: 1. Thickness variation. 2. Excessive corrosion. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 7461 Rotor thickness variation is the result of uneven rotor wear caused by excessive lateral runout (>0.076 mm; >0.003 in.). Lateral runout can be induced by: 1. Distortion of the braking surface by applying uneven and/or excessive wheel nut torque. (This could be the result of a recent tire change, rotation, etc.). 2. Improperly refacing rotors. Brake Noise Important: SOME BRAKE NOISE IS NORMAL. Brake noise is caused by a "slip stick" type vibration of brake components. Some intermittent brake noise may be normal. Performing 3-4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists, a brake dampening compound may be applied to the back of each pad. Use Permatex Disc Brake Quiet # 126HB or equivalent. Also, clean and lube all metal-to-metal contact areas between pads, pad guides, caliper and knuckles with a thin layer of high temperature silicone grease. This allows parts to slide freely and not vibrate when moving relative to each other. Rotor Grooving Excessive grooving can be caused by foreign material in contact with the rotor, but most often rotor grooving is the result of normal brake wear. DO NOT RESURFACE ROTORS FOR LIGHT GROOVING. Resurface rotors only when grooves of 1.5 mm (0.060 in.) or deeper are present. A dime may be used to determine disc brake groove depth. Place a dime in the groove, with Roosevelt's head toward the groove. If the dime goes into the groove beyond the top of his head, the groove exceeds 1.5 mm (0.060 in.) and the rotor should be serviced. (In Canada, if any portion of the letters of "In Canada" are covered, the rotor should serviced.) It the groove is too narrow for the dime to be inserted, it is not a cause for concern. High Pedal Effort Follow Service Manual diagnostic procedures for this condition. Service rotors if they have been recently resurfaced. (The surface finish may be out-of-specification). Lightly Rusted Rotors Light surface rust on rotor braking surfaces is often cosmetic and can be eliminated during a few normal driving stops. Rusting may occur when a vehicle is not driven for extended periods. Rotors with surface rust on unsold new cars can usually be burnished clean by performing 15 moderate stops from 62-75 km/h (35-40 mph) with cooling time between stops. Facts About Brake Service ^ Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. New rotors should not be resurfaced before installation. ^ Improper tightening of wheel nuts can induce lateral runout (distortion of braking surfaces) which will lead to uneven wear. As high spots are worn down, resulting thickness variation will cause brake pulsation. ^ Ensure wheel bearing flange is clean and free of corrosion before installing new rotors. A new essential tool (Kent Moore tool J 42450) will soon be sent to all dealers. This tool makes it easier to clean corrosion around the wheel studs. ^ Always mark the position of rotor on the hub before removal, and reinstall the rotor in the same position. ^ Rotors with perceived hard spots or discoloration should not be serviced. These conditions are normal. ^ Installation of new rotors does not require pad replacement. Do NOT replace pads unless their condition requires it. ^ It is NOT necessary to replace rotors in pairs. Rotors may be serviced individually. ^ A TORQUE LIMITING SOCKET OR TORQUE WRENCH MUST BE USED to insure that the wheel nuts are tightened to specification. This should be done in 3 steps using the star pattern. 1. Snug the nuts down by hand. 2. Using the star pattern and a torque limiting socket or torque wrench, tighten the wheel nuts to about half the final torque. 3. Tighten the wheel nuts to specification using the star pattern and a torque limiting socket or torque wrench. ^ NEVER use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces. Wheel nuts, studs, and mounting surfaces must be clean and dry. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > General Rotor Specifications Brake Rotor/Disc: Specifications Rotor Diameter 10.197 in Lateral Runout 0.003 in Thickness Variation 0.0005 in Rotor Thickness (new) 0.786 in Minimum Thickness after Refinish 0.751 in Discard Thickness 0.736 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > General Rotor Specifications > Page 7464 Brake Rotor/Disc: Specifications Rotor Diameter 10.197 in Lateral Runout 0.003 in Thickness Variation 0.0005 in Rotor Thickness (new) 0.786 in Minimum Thickness after Refinish 0.751 in Discard Thickness 0.736 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Rotor Tolerance and Surface Finish Brake Rotor/Disc: Testing and Inspection Rotor Tolerance and Surface Finish In manufacturing the brake rotor, tolerances of the braking surfaces for flatness, parallelism and lateral runout are closely held. The maintenance of close tolerances on the shape of the braking surfaces is necessary to prevent brake roughness or pulsation. In addition to these tolerances, the surface finish must be held to a specific range. This range is 60 Ra roughness or less. The control of the braking surface finish is necessary to avoid problems of hard pedal apply, excessive brake fade, pulls and erratic performance. In addition, control of the surface finish can improve lining life. Light scoring of the rotor surfaces not exceeding 1.5 mm (0.06 inches) in depth, which may result from normal use, is not detrimental to brake operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Rotor Tolerance and Surface Finish > Page 7467 Brake Rotor/Disc: Testing and Inspection Thickness Variation Check Check thickness variation by measuring the rotor thickness at four or more points around the circumference of the rotor. Use a micrometer calibrated in ten-thousands of an inch. Make all measurements at the same distance in from the edge of the rotor. A rotor that varies in thickness by more than 0.013 mm (0.0005 inches) can cause pedal pulsation and/or front end vibration during brake applications. A rotor that does not meet these specifications should be refinished to specifications or replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Rotor Tolerance and Surface Finish > Page 7468 Brake Rotor/Disc: Testing and Inspection Lateral Runout Check NOTE: The best way to check lateral runout is with the wheels still installed on the vehicle. This gives a much more accurate reading of the Total Indicated Runout (T.I.R.) under real breaking conditions. If equipment is not available to perform the check with the wheels installed, the next best reading can be made with the wheels removed but with the caliper still installed. 1. Clean rotor surface. If the wheel must be moved, re-install the wheel nuts to retain the rotor. Tighten the wheel nuts to the correct tightening specification following the wheel nut tightening sequence. 2. Fasten a dial indicator to the steering knuckle so that the indicator button contacts the rotor surface about 13 mm (0.5 inches) from the outer edge. 3. Set the dial indicator to zero. 4. Turn the wheel one complete revolution and observe the runout indicated on the dial. The T.I.R. must not exceed 0.008 mm (0.003 inches). In some cases, excessive lateral runout of the rotor can be improved by indexing the rotor on the hub one or two bolt positions from the original position. If the lateral runout cannot be corrected by indexing the rotor, check the hub and bearing assembly for excessive lateral runout or looseness. If the hub and bearing assembly lateral runout exceeds 0.040 mm (0.0015 inches), then replace the hub and bearing assembly. If lateral runout is within specifications then refmish or replace the rotor as necessary. NOTE: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the wheel bearing flange and rotor. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 5. If lateral runout exceeds the amount specified in step 4, refinish or replace the rotor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Page 7469 Brake Rotor/Disc: Service and Repair NOTE: ^ DO NOT refinish brake rotors when performing routine brake maintenance such as replacing worn disc brake pads. ^ Refinish a rotor only under the following circumstances: There is a complaint of brake pulsation. - There are heat spots or excessive scoring. REFINISHING BRAKE ROTORS All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet specifications. Refinished Too Thin A rotor which has been refinished too thin will not have proper heat transfer capabilities. Replace it with a new brake rotor. Accurate control for the rotor tolerances is necessary for proper performance of the disc brakes. Use Only Precision Equipment Machining of rotors should be done only with precision equipment. The equipment should be serviced on a regular basis following the manufacturer's recommended maintenance procedure. When refinishing rotors, the attaching adapters, tool holders, vibration dampeners, and tool bits must be in good condition. Always use sharp cutting tools or bits and use only replacement cutting bits recommended by the equipment manufacturer. Dull or worn tools leave a poor surface finish which will affect initial braking performance. NOTE: Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in a better surface finish. Make sure adapters are clean and free of nicks. ON-VEHICLE REFINISHING In the cases where rotors are being refinished to correct a problem with brake pulsation, it is recommended that an On-Vehicle brake lathe be used to achieve best results. Follow the lathe manufacturer's recommended specifications and procedure. Off-Vehicle Refinishing OFF-VEHICLE REFINISHING Refer to chart showing two recommended procedures that achieve adequate results using two different vendor's off-vehicle drum/disc brake lathes (If any other vendor's lathe is used, follow that vendor's recommended procedure). It is very important that the rotor surface be made non-directional by dressing the rotor surfaces with a sanding disc power tool such as Ammco 8350 Safe Swirl Disc Rotor Grinder, or equivalent, using 120 grit aluminum oxide sandpaper. Sand each rotor surface with moderate pressure for a minimum of 60 seconds. An alternate method is to use a sanding block with 150 grit aluminum oxide sandpaper. With the rotor turning approximately 150 RPM, sand each rotor finish for a minimum of 60 seconds using moderate pressure. After the rotor has been sanded, clean each surface with denatured alcohol or suitable brake cleaner. The finish rotor surface should be as close to that of a new rotor as possible. Failure to obtain the best possible rotor finish may affect initial braking performance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Page 7470 NOTE: After brake pads have been replaced and/or rotors have been refinished, it is recommended that the new braking surface be broken in, or burnished. This can be accomplished by making 20 stops from 30 mph, using medium to firm pedal pressure with a minimum of 15 seconds between stops. Take care to avoid overheating the brakes. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 00-05-24-001 > Apr > 00 > Rear Drum Brakes - Sticking/Won't Release Backing Plate: Customer Interest Rear Drum Brakes - Sticking/Won't Release File in Section: 05 - Brakes Bulletin No.: 00-05-24-001 Date: April, 2000 TECHNICAL Subject: Snow Intrusion Into Rear Drum Brake Assemblies Models: 1985-87 Buick Somerset 1985-89 Buick Skyhawk 1985-98 Buick Skylark 1985-88 Cadillac Cimarron 1985-2000 Chevrolet Cavalier 1985-88 Oldsmobile Firenza 1985-91 Oldsmobile Cutlass Calais 1992-98 Oldsmobile Achieva 1985-94 Pontiac Sunbird 1985-98 Pontiac Grand Am 1995-2000 Pontiac Sunfire Condition: Some customers may comment that after operating their vehicle in snow and then parking the vehicle for an extended period, the rear brakes appear to remain applied. Cause: On rare occasions, light powdery snow may enter one or both of the vehicle's rear drum brake assemblies. If the vehicle is parked prior to the snow melt (water) being expelled, this may result in the rear brake shoe(s) adhering/freezing to the brake drum(s). Normally, the brake shoe(s) will break free of the drum upon placing the vehicle in gear. However, cases have been noted where vehicle movement has been restricted until the brake assemblies have had an opportunity to thaw. Correction: Replace existing rear brake backing plates with new backing plates, P/N 18015841. Refer to the Drum Brakes sub-section in the Service Manual for replacement procedures. Parts Information Parts are expected to be available from GMSPO, April 10, 2000. Warranty Information For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 00-05-24-001 > Apr > 00 > Rear Drum Brakes - Sticking/Won't Release Backing Plate: All Technical Service Bulletins Rear Drum Brakes - Sticking/Won't Release File in Section: 05 - Brakes Bulletin No.: 00-05-24-001 Date: April, 2000 TECHNICAL Subject: Snow Intrusion Into Rear Drum Brake Assemblies Models: 1985-87 Buick Somerset 1985-89 Buick Skyhawk 1985-98 Buick Skylark 1985-88 Cadillac Cimarron 1985-2000 Chevrolet Cavalier 1985-88 Oldsmobile Firenza 1985-91 Oldsmobile Cutlass Calais 1992-98 Oldsmobile Achieva 1985-94 Pontiac Sunbird 1985-98 Pontiac Grand Am 1995-2000 Pontiac Sunfire Condition: Some customers may comment that after operating their vehicle in snow and then parking the vehicle for an extended period, the rear brakes appear to remain applied. Cause: On rare occasions, light powdery snow may enter one or both of the vehicle's rear drum brake assemblies. If the vehicle is parked prior to the snow melt (water) being expelled, this may result in the rear brake shoe(s) adhering/freezing to the brake drum(s). Normally, the brake shoe(s) will break free of the drum upon placing the vehicle in gear. However, cases have been noted where vehicle movement has been restricted until the brake assemblies have had an opportunity to thaw. Correction: Replace existing rear brake backing plates with new backing plates, P/N 18015841. Refer to the Drum Brakes sub-section in the Service Manual for replacement procedures. Parts Information Parts are expected to be available from GMSPO, April 10, 2000. Warranty Information For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications All brake drums and rotors have a discard dimension cast into them. This is a wear dimension and not a refinish dimension. Any drum or rotor which does not meet the specification should be replaced. Inside Diameter 7.874-7.890 in Runout 0.006 in Maximum Re-bore Diameter 7.899 in Discard Diameter 7.929 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 7488 Anchor Plate Drum Brake Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Cracked, Scored, or Grooved Drum Brake Drum: Testing and Inspection Cracked, Scored, or Grooved Drum A cracked drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Smooth up any slight scores. Heavy or extensive scoring will cause excessive brake lining wear, and it may be necessary to refinish the drum braking surface. If the brake linings are slightly worn (but still re-usable) and the drum is grooved, polish the drum with fine emery cloth, but do not refinish. Eliminating all grooves in brake drums and smoothing ridges on brake linings would require the removal of too much metal and lining. If left alone, the grooves and ridges match and satisfactory service can be obtained. If brake linings are to be replaced, always refinish a grooved drum. A grooved drum, if used with a new lining, will wear the lining and make proper brake performance difficult to obtain. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Cracked, Scored, or Grooved Drum > Page 7491 Brake Drum: Testing and Inspection Brake Drum Balance During manufacture, weights are used to balance brake drums. Do not remove these weights. When having a problem with wheel balancing, especially after drums have been refinished, check the drums for balance. They can be checked on most off-vehicle balancers. If found to be out of balance, replace the drum. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Cracked, Scored, or Grooved Drum > Page 7492 Brake Drum: Testing and Inspection Out-of-Round or Tapered Drum An out-of-round or tapered drum prevents accurate brake shoe adjustment and is likely to cause excessive wear of other brake parts due to its eccentric action. An out-of-round drum can also cause severe and irregular tire tread wear as well as a pulsating brake pedal. When the drum exceeds the specification limits in taper and/or out-of-round, refinish the drum to true up the braking surface. Out-of-round, as well as taper and wear, can be accurately measured with an inside micrometer and extension rods. When measuring a drum for out-of-round, taper and wear, take measurements at the open and closed edges of the machined surface and at right angles to each other. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement Brake Drum: Service and Repair Brake Drum Replacement Anchor Plate Drum Brake Assembly NOTE: ^ When installing new brake drums do not refinish the braking surface as these parts are at the correct level of surface finish. Install all new components included in the repair kit used to service drum brakes. Lubricate parts as specified. Do not use lubricated compressed air on brake parts as damage to rubber components may result. If any hydraulic component is removed or disconnected, it will be necessary to bleed all or part Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7495 of the brake system. Replace shoe and linings in axle sets only. The fastener tightening specifications are for dry, unlubricated fasteners. Perform service operations on a clean bench, free from all mineral oil materials. ^ Raise vehicle and suitably support. Mark relationship of wheel to axle flange to insure proper wheel balance upon assembly. Mark relationship of brake drum to axle flange to insure proper wheel balance upon assembly. REMOVE OR DISCONNECT 1. Tire and wheel assembly. 2. Brake drum. If difficulty is encountered in removing the brake drum, the following steps may be of assistance. Make sure parking brake is released. Back off parking brake cable adjustment. Use a rubber mallet to tap gently on outer rim of the drum and/or around inner drum diameter by spindle. Take care not to deform the drum by use of excessive force. 3. Return springs using J 8049 or J 29840 pliers. 4. Hold-down springs and pins using suitable pliers. 5. Actuator link while lifting up on actuator lever. Bearing Sleeve Location 6. Actuator lever, lever return spring and bearing sleeve. 7. Parking brake strut and strut spring. 8. Shoe and lining assemblies after disconnecting parking brake cable. 9. Adjusting screw assembly and adjusting screw spring. 10. Retaining ring, pin and parking brake lever from secondary shoe. If any parts are of doubtful strength or quality due to discoloration from heat, over-stress, or worn, the parts should be replaced. Clean before reinstalling adjusting screw assembly it must be disassembled, thoroughly cleaned and lubricated. Clean adjusting screw threads with a wire brush. Wash all components in clean denatured alcohol. Apply brake lubricant to the adjusting screw threads, inside diameter of socket and socket face. Adequate lubrication is achieved when a continuous bead of lubricant is at open end of pivot nut and socket when threads are fully engaged. Lubricate 6 pads on backing plate where brake shoes contact backing plate. Inspect threads of adjusting screw for smooth rotation over full length. INSTALL OR CONNECT 1. Parking brake lever on secondary shoe with pin and retaining ring. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7496 Adjusting Screw Assembly 2. Adjusting screw assembly and adjusting screw spring. 3. Shoe and lining assemblies after attaching parking brake cable. 4. Parking brake strut and strut spring by spreading shoes apart. NOTE: To properly position: ^ The end without the strut spring should engage the parking brake lever and secondary shoe and lining. ^ The end with the strut spring should engage the primary shoe and lining. 5. Bearing sleeve, actuator lever and lever return spring. NOTE: The bearing sleeve must be installed between the secondary shoe and lining and the actuator lever. 6. Hold-down pins and hold-down springs. 7. Actuator link on anchor pin. 8. Actuator link into actuator lever while holding up on lever. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7497 Measuring Drum And Shoe For Adjustment 9. Shoe return springs using J 8057 pliers. Adjust Brakes. See: Adjustments 10. Brake drum, aligning previous marks. 11. Tire and wheel assembly. 12. Lower vehicle. 13. Tighten wheel nuts to specified torque. Adjust parking brake. See: Parking Brake System/Adjustments Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 7498 Brake Drum: Service and Repair Refinishing Brake Drums DO NOT REMOVE TO MUCH METAL If a drum must be refinished, remove only enough metal to obtain a true, smooth braking surface. If a drum does not clean-up when refinished to a maximum re-bore diameter, replace it. Removal of more metal will affect heat dissipation and may cause drum distortion. MAXIMUM DIAMETER CAST IN All brake drums have a maximum diameter cast into them. This diameter is the maximum wear diameter and not a finish diameter. When refinishing a brake drum, resurface the drum to no more than a dimension of 0.76 mm (0.O3O inch) less than the discard diameter. REFINISH DIAMETER The refinish diameter is the maximum diameter the brake drum may be refinished to and still allow safe braking action. If this dimension is exceeded, the brake drum will wear beyond the discard diameter during normal brake wear. PROPER TOOLS Always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Always use vibration dampening attachments when refinishing braking surfaces. These attachments eliminate tool chatter so a better finish can be obtained. The optimum speed for refinishing braking surfaces is a spindle speed of 150 rpm. Crossfeed for rough cutting should range from 0.15-0.25 mm (0.006-0.010 inches) per revolution. Finish cuts should be made at crossfeeds no greater than 0.05 mm (0.002 inches) per revolution. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications For riveted linings, measure depth from lining surface to head of rivet. Discard linings if there is 0.030 inch or less from braking surface to the top of any rivet head. Minimum Thickness 0.030 in Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7506 Wheel Cylinder: Specifications Wheel Cylinder Bore Diameter 0.689 in Wheel Cylinder To Backing Plate 15 ft.lb Wheel Cylinder Bleeder Screw 62 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7507 Anchor Plate Drum Brake Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7508 Wheel Cylinder Components Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Overhaul Wheel Cylinder: Service and Repair Overhaul Wheel Cylinder Components NOTE: Remove wheel cylinder. Refer to Wheel Cylinder replace. DISASSEMBLE 1. Boots. 2. Pistons and seals. 3. Spring assembly. 4. Bleeder valve. Inspect cylinder bore and pistons for scoring, nicks, corrosion and wear. Use crocus cloth to polish out light corrosion. Replace wheel cylinder assembly if bore will not clean up with crocus cloth. 5. Clean all parts in clean denatured alcohol. Dry parts with unlubricated compressed air. Lubricate new seals with clean brake fluid. ASSEMBLE 1. Bleeder valve. Tighten bleeder valve to 7 Nm (62 inch lbs.). 2. Spring assembly. 3. Seals, pistons and boots. 4. Install wheel cylinder to vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Overhaul > Page 7511 Wheel Cylinder: Service and Repair Replace Anchor Plate Drum Brake Assembly NOTE: Clean dirt and foreign material around wheel cylinder assembly inlet and pilot. REMOVE OR DISCONNECT 1. Inlet tube nut and line. Plug opening in line to prevent fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Overhaul > Page 7512 2. Brake drum. 3. Hub and bearing assembly. 4. Pull backing plate away from axle flange. Do not let backing plate hang from parking brake cable. Damage may occur. 5. Wheel cylinder bolts using a #6 Torx socket. 6. Wheel cylinder. Wheel Cylinder Components INSTALL OR CONNECT 1. Wheel cylinder bolts using a #6 Torx socket. Tighten wheel cylinder bolts to 20 Nm (15 ft. lbs.). 2. Backing plate to axle flange. 3. Hub and bearing assembly. 4. Brake drum. 5. Inlet tube line and nut. Tighten inlet tube nut to 23 Nm (17 ft. lbs.). 6. Bleed wheel cylinder. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System Brake Bleeding: Service and Repair Bleeding Brake Hydraulic System Scan Tool Method 1. Using a scan tool, select MOTOR REHOME. The motor rehome function cannot be performed if current DTCs are present. If DTCs are present, the vehicle must be repaired and DTCs cleared before performing the motor rehome function. 2. The entire brake system can now be bled. Without Scan Tool NOTE: This method can only be used if the ABS indicator lamp is not illuminated and no DTCs are present. Do not place your foot on the brake pedal through this entire procedure unless specifically directed to do so. 1. Remove foot from brake pedal. 2. Start engine and allow it to run for at least 10 seconds while observing the ABS indicator lamp. 3. If the ABS indicator lamp turned ON and stayed ON after about 10 seconds, a scan tool must be used to diagnose the ABS malfunction. 4. If the ABS indicator lamp turned ON for approximately 3 seconds, then turned OFF and stayed OFF, turn the ignition OFF. 5. Repeat Steps 1 through 4 one more time. 6. The entire brake system can now be bled. General Information WARNING: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause loss of brakes with possible personal injury. REMOVING AIR FROM THE SYSTEM A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the brake system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipe at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If pipes are disconnected at any fitting located between master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. The time required to bleed the hydraulic system can be reduced if the master cylinder reservoir is filled with brake fluid and as much air as possible is expelled before the master cylinder is installed on the vehicle. Pressure Bleeding Master Cylinder Pressure Bleeding Adapter NOTE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system. 1. Install J 35589 to the master cylinder. 2. Charge J 29532 to 140-172 kPa (20-25 psi). 3. Connect line to J 35589 and open line valve. 4. Raise vehicle and suitably support. 5. If it is necessary to bleed all of the calipers/cylinders, the following sequence should be followed: Right rear Left rear Right front Left front 6. Place a proper size box end wrench (or J 21472) over the caliper/cylinder bleeder valve. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System > Page 7518 7. Attach a clear tube over the bleeder screw. Submerge the other end of the tube in a clear container partially filled with clean brake fluid. 8. Open the bleeder screw at least 3/4 of a turn and allow flow to continue until no air is seen in the fluid. 9. Close the bleeder screw.Tighten Rear bleeder screws to 7 Nm (62 inch lbs.) and Front bleeder screws to 13 Nm (115 inch lbs.) 10. Repeat Steps 6 through 9 until all calipers/cylinders have been bled. 11. Lower vehicle. 12. Check the brake pedal for "sponginess." Repeat entire bleeding procedure to correct either of these two conditions. 13. Remove J 35589 and J 29532. 14. Fill the master cylinder to the proper level. Manual Bleeding Deplete the vacuum reserve by applying, the brakes several times with the ignition "Off". Use extreme care to prevent brake fluid from contacting painted surfaces. 1. Fill the master cylinder reservoir with brake fluid. Maintain the fluid level in the reservoir during the bleeding operation. It is necessary to have an assistant in the vehicle to press on the brake pedal during the manual bleeding procedure. 2. If the master cylinder is known or suspected to have air in the bore, then it must be bled before any wheel cylinder or caliper in the following manner: a. Disconnect the front brake pipe connection(s) at the master cylinder. b. Allow brake fluid to fill the master cylinder until it begins to flow from the front pipe connector port. c. Connect the forward brake pipe(s) to the master cylinder and tighten. d. Depress the brake pedal slowly one time and hold. Loosen the front brake pipe connection at the master cylinder to purge air from the bore. Tighten the connection and then release the brake pedal slowly. Wait 15 seconds. Repeat the sequence, including the 15 second wait, until all air is removed from the bore. Care must be taken to prevent brake fluid from contacting any painted surface. After all air has been removed at the forward connection(s), bleed the master cylinder at the rear (cowl) connection(s) in the same manner as the front. e. If it is known that the calipers and wheel cylinders do not contain any air, then it will not be necessary to bleed them. 3. Individual wheel cylinder or calipers are bled only after all air is removed from the master cylinder. 4. If is necessary to bleed all of the wheel circuits, the following sequence should be followed: 1st - Right rear / 2nd - Left rear / 3rd - Right front / 4th - Left front 5. Raise vehicle.. 6. Place a proper size box end wrench (or special tool) over the caliper/cylinder bleeder valve. 7. Attach a clear tube over the bleeder screw. Submerge the other end of the tube in a clear container partially filled with clean brake fluid. 8. Depress the brake pedal slowly one time and hold. Loosen the bleeder screw to purge air from the cylinder/caliper. Tighten bleeder screw and slowly release pedal. Wait 15 seconds. Repeat the sequence, including the 15 second wait, until all air is removed. It may be necessary to repeat the sequence 10 or more times to remove all the air. Rapid pumping of the brake pedal pushes the master cylinder secondary piston down the bore in a way that makes it difficult to bleed the system. Tighten rear bleeder screws to 7 Nm (62 inch lbs.) and front bleeder screws to 13 Nm (115 inch lbs.) 9. Lower vehicle. 10. Fill the master cylinder to the proper level. 11. Check the brake pedal for "sponginess" or excessive travel. Repeat entire bleeding procedure to correct either of these two conditions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding Brake Hydraulic System > Page 7519 Brake Bleeding: Service and Repair Flushing Brake Hydraulic System The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contains the slightest trace of petroleum or mineral based fluids. All rubber parts, including the brake hoses, that have been exposed to contaminated fluid must be replaced. Approximately one quart of fluid is required to flush the hydraulic system. When flushing the system use the steps specified in pressure bleeding procedures shown in "Bleeding Brake Hydraulic System." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Mounting Bolt and Sleeve Assembly 38 ft.lb Caliper Inlet Fitting 34 ft.lb Caliper Bleeder Valve 115 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Technician Safety Information Brake Caliper: Technician Safety Information CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, or by cleaning brake parts with a dry brush or with compressed air. Many brake parts contain asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment is commercially available to perform this washing function. These wet methods will prevent asbestos fibers from becoming airborne. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Technician Safety Information > Page 7525 Brake Caliper: Vehicle Damage Warnings NOTE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener tightening specification and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Page 7526 Brake Caliper: Description and Operation This caliper has a single bore and is mounted to the steering knuckle with two mounting bolts. Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the caliper piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward resulting in a clamping action on the rotor. This clamping action forces the linings against the rotor, creating friction to stop the vehicle. NOTE: Install all new components included in the repair kit used to service this caliper. Lubricate rubber parts with clean brake fluid to ease assembly. Do not use lubricated compressed air on brake parts as damage to rubber components may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. Replace shoe and linings in axle sets only. The tightening specifications are for dry, unlubricated fasteners. Perform service operations on a clean bench, free from all mineral oil materials. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Replacement Brake Caliper: Service and Repair Caliper Replacement NOTE: Install all new components included in the repair kit used to service this caliper. Lubricate rubber parts with clean brake fluid to ease assembly. Do not use lubricated compressed air on brake parts as damage to rubber components may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. Replace shoe and linings in axle sets only. The tightening specifications are for dry, unlubricated fasteners. Perform service operations on a clean bench, free from all mineral oil materials. Disc Brake Caliper Assembly REMOVE OR DISCONNECT 1. Remove 2/3 of brake fluid from master cylinder assembly. 2. Raise vehicle and suitably support. Mark relationship of wheel to hub and bearing assembly, to insure proper wheel balance upon reassembly. 3. Tire and wheel assembly. Reinstall two wheel nuts to retain rotor to hub and bearing assembly. Compressing Piston 4. Push piston into caliper bore to provide clearance between linings and rotor. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe. Slowly tighten C-clamp until piston is pushed into the caliper bore enough to slide the caliper assembly off rotor. 5. Bolt attaching inlet fitting only when caliper is to be removed from vehicle for unit repair (overhaul). If only shoe and linings are being replaced, there is no need to disconnect inlet fitting. Plug exposed inlet fitting in caliper housing and brake hose to prevent fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7529 Caliper Mounting 6. Caliper mounting bolts and sleeve assemblies. Suspending Caliper 7. Caliper from rotor and knuckle. Do not let caliper hang from brake hose. Damage may occur. If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut. Inspect mounting bolts and sleeve assemblies for corrosion. Bushings for cuts or nicks. If damage to either part is found, replace with new parts when installing caliper. Do not attempt to polish away corrosion. INSTALL OR CONNECT Lubricating Caliper Cavity 1. Liberally coat inside diameter of bushings with silicone grease. 2. Mounting bolts and sleeve assemblies. 3. Caliper over rotor into knuckle. Tighten mounting bolt and sleeve assemblies to 51 Nm (38 ft. lbs.). 4. Inlet fitting, if removed. Tighten inlet fitting to 44 Nm (32 ft. lbs.). 5. Wheel and tire, aligning previous marks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7530 a. Remove wheel nuts securing rotor to hub and bearing assembly. b. Install wheel and tire assembly with retaining nuts in proper sequence. c. Lower the vehicle. d. Torque wheel nuts. 6. Fill master cylinder to proper level with clean brake fluid. Bleed caliper if inlet fitting was removed. Recheck fluid level. Recheck brake pedal feel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7531 Brake Caliper: Service and Repair Caliper Overhaul Caliper Assembly DISASSEMBLE 1. Remove caliper completely from vehicle. See: Caliper Replacement 2. Bushings. Inspect bushings for cuts and nicks. Replace if damaged. Use clean shop towels to pad the interior of the caliper housing during removal. WARNING: On the following procedure do not place fingers in front of the piston in an attempt to catch or protect it when applying compressed air. This could result in serious injury. Removing Caliper Piston 3. Piston using compressed air into the caliper inlet hole. Inspect piston for scoring, nicks, corrosion and worn or damaged chrome plating. Replace piston if any of these conditions are found. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7532 Removing Boot 4. Boot from caliper housing bore. Be careful not to scratch housing bore. 5. Piston seal from seal groove in caliper housing bore with a small wood or plastic tool.Inspect caliper housing bore and seal groove for scoring, nicks, corrosion and wear. Use crocus cloth to polish out light corrosion. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth. CAUTION: Do not use a metal tool since this may damage caliper bore or seal groove. 6. Bleeder valve and bleeder valve cap from caliper. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. Blow out all passages in caliper housing and bleeder valve. ASSEMBLE 1. Bleeder valve and bleeder valve cap into caliper. Tighten bleeder valve to 13 Nm (115 inch lbs.). 2. Lubricate new piston seal and install into caliper bore groove. Make sure seal is not twisted. Installing Boot Onto Piston 3. Lubricated boot onto piston. 4. Piston and boot into bore of caliper and push to bottom of bore. Seating Boot Into Caliper Housing 5. Seat boot in caliper housing counter bore using J 29077-A. 6. Bushings. Lubricate beveled end of bushing with silicone grease. Pinch bushing and install bevel end first. Push bushing through housing mounting bore. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Replacement > Page 7533 7. Caliper. See: Caliper Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 7534 Brake Caliper: Tools and Equipment Special Tools Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 7539 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 7540 Brake Fluid: Specifications Brake System DOT 3 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations Fluid Level Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations > Page 7545 LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7546 Brake Fluid Level Sensor/Switch: Description and Operation The master cylinder is equipped with a fluid level switch located in the side of the master cylinder reservoir. This switch will activate the red "BRAKE" light if a low fluid condition is detected. Once the fluid level is corrected the "BRAKE" light will go out. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7547 Brake Fluid Level Sensor/Switch: Service and Repair Fluid Level Switch REMOVE OR DISCONNECT 1. Electrical connector from fluid level switch. Proportioner Valves 2. Fluid level switch using needle nose pliers to compress switch locking tabs at inboard side of master cylinder reservoir. INSTALL OR CONNECT 1. Fluid level switch into master cylinder reservoir until locking tabs snap in place. 2. Electrical connector to fluid level switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Line Brake Hose/Line: Specifications Brake Line Brake Lines At Master Cylinder ........................................................................................................... .................................................... 23 Nm (17 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Line > Page 7552 Brake Hose/Line: Specifications Brake Hose Brake Hose To Caliper ........................................................................................................................ ..................................................... 44 Nm (32 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7553 Brake Hose/Line: Locations Rear Brake Pipes Front Brake Pipes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7554 Rear Brake Pipes And Hoses Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions > Pipe Replacement Brake Hose/Line: Service Precautions Pipe Replacement WARNING: ^ Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. ^ Do not use single lap flaring tools. Double lap flaring tools must be used to produce a flare strong enough to hold the system pressure. Using lap single flaring tools could cause system damage and cause brake system failure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions > Pipe Replacement > Page 7557 Brake Hose/Line: Service Precautions Component Damage CAUTION: Never allow brake components such as calipers to hang from the flexible hoses as damage to the hoses may occur. Some brake hoses have protective rings or covers to prevent direct contact of the hose with other chassis parts. Besides causing possible structural damage to the hose, excessive tension could cause the hose rings to move out of their proper locations. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions > Page 7558 Brake Hose/Line: Testing and Inspection Front Brake Hoses Rear Brake Pipes And Hoses Hydraulic brake hoses should be inspected at least twice a year. Check brake hose assemblies for: ^ Road hazard damage. ^ Cracks and chafing of outer cover. ^ Leaks and blisters. ^ Proper routing and mounting. NOTE: If you find any of these conditions, adjust or replace the hose assembly. A brake hose which rubs on other components will wear and eventually fail. A light and mirror can be helpful to thoroughly inspect the hose assemblies. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions > Page 7559 Brake Hose/Line: Service and Repair 1. Obtain the recommended pipe and steel fitting nuts of the correct size. Outside diameter of pipe is used to specify size. 2. Cut pipe to length with a pipe cutter. Do not force the cutter, advance the tool only a small amount per turn of the tool. Correct length of pipe may be determined by measuring old pipe using a string and adding 3.2 mm (1/8 inch) for each ISO flare. 3. Make sure fittings are installed before starting flare. 4. Chamfer the inside and outside diameter of the pipe with the de-burring tool. 5. Remove all traces of lubricant from brake pipe and flaring tool. 6. Clamp the flaring tool body in vise. 7. Select the correct size collet and forming mandrel for pipe size used. Forming Mandrel And Forcing Screw 8. Insert the proper forming mandrel into the tool body. While holding forming mandrel in place with your finger, thread in the forcing screw until it makes contact and begins to move the forming mandrel. When contact is made, turn the forcing screw back one complete turn. 9. Slide the clamping nut over the brake pipe and insert the prepared brake pipe into the correct collet. Leave approximately 19 mm (0.750 inch) of tubing extending out the collet. Insert the assembly into the tool body. The brake pipe end must contact the face of the forming mandrel. Clamping Nut And Collet 10. Tighten the clamping nut into the tool body very tight or the pipe may push out. 11. Wrench tighten the forcing screw in until it bottoms. Do not over tighten the forcing screw or the flare may become over-sized. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions > Page 7560 ISO Flare 12. Back the clamping nut out of the tool body and disassemble the clamping nut and collet assembly. the flare is now ready for use. 13. Bend pipe assembly to match old pipe. Clearance of 19 mm (0.750 inch) must be maintained to all moving or vibrating parts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation The proportioner valve limits outlet pressure to the rear brakes after a predetermined master cylinder pressure has been reached. This is used when less rear apply force is needed to obtain optimum braking. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 7564 Brake Proportioning/Combination Valve: Service and Repair Compact Master Cylinder REMOVE OR DISCONNECT 1. Proportioner valve caps. In order to remove the proportioner valve caps, it may be necessary to remove the master cylinder reservoir. 2. Proportioner valve cap "O"-rings and discard. 3. Proportioner valve piston springs. 4. Proportioner valve pistons. Use needle nose pliers with care not to scratch or otherwise damage piston stems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 7565 5. Proportioner valve seals from proportioner valve pistons. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. Inspect proportioner valve pistons for corrosion, or deformation and replace if found. NOTE: Lubricate new proportioner valve cap "O"-rings and proportioner valve seals with silicone grease supplied in repair kit. Also lubricate stem of proportioner valve pistons. Unlocking Switch Tabs INSTALL OR CONNECT 1. New proportioner valve seals on proportioner valve pistons with seal lips facing upward toward proportioner valve cap. 2. Proportioner valve pistons and seals in master cylinder body. 3. Proportioner valve piston springs in master cylinder body. 4. New proportioner valve cap "0" -rings in grooves in proportioner valve caps. 5. Proportioner valve caps in master cylinder body. Tighten proportioner valve caps to 27 Nm (20 ft. lbs.). 6. Master cylinder reservoir, if removed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Component Locations > Page 7570 LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control > Component Information > Locations > Page 7571 Hydraulic Assembly: Diagrams LH Rear Engine Compartment-Front Of Dash ABS Actuator Motor Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7580 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7581 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7587 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Control Assembly - Antilock Brakes: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7588 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > ABS Tightening Specifications Brake Master Cylinder: Specifications ABS Tightening Specifications FASTENER TIGHTENING SPECIFICATIONS Brake Pipe Tube Nuts ......................................................................................................................... ............................................. 24Nm (18 ft. lbs.) Gear Cover Torx Head Screws ...................................................................................................................................................... 4 Nm (36 inch lbs.) Hydraulic Modulator: Bleeder Valves .................................................................................................................................... .................................... 9 Nm (80 inch lbs.) Solenoid Torx Head Bolt ........................................................................................................................................................ 5 Nm (44 inch lbs.) Master Cylinder Threw Bolts ................................................................................................................................................... 24 Nm (18 ft. lbs.) Motor Pack Torx Head Screws ..................................................................................................................................................... 5 Nm (44 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > ABS Tightening Specifications > Page 7593 Brake Master Cylinder: Specifications Tightening Specifications DIMENSIONS Master Cylinder Bore Diameter .......................................................................................................................................... 22.20 mm (0.874 inches) FASTENER TIGHTENING SPECIFICATIONS Proportioner Valve Caps ..................................................................................................................... ........................................... 27 Nm (20 ft. lbs.) Brake Pipe Tube Nuts ................................................ ..................................................................................................................... 23 Nm (17 ft. lbs.) Master Cylinder Assembly To Power Booster Nuts ....................................................................................................................... 27 Nm (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7594 Compact Master Cylinder Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service Precautions > Technician Safety Information Brake Master Cylinder: Technician Safety Information Chemical Warning WARNING: ^ Brake fluid may irritate eyes and skin. In case of contact, take the following actions: Eye contact: rinse thoroughly with water. - Skin contact: wash with soap and water. - If ingested: consult a physician immediately. ^ To help avoid personal injury, due to a retained load on the hydraulic modulator, the GEAR TENSION RELIEF function of the scan tool must be performed prior to removal of the ABS hydraulic modulator/master cylinder assembly. Fluid Warning WARNING: ^ Brake fluid may irritate eyes and skin. In case of contact, take the following actions. Eye contact - rinse thoroughly with water. Skin contact - wash with soap and water. If ingested consult a physician Immediately ^ Certain components in the Antilock Brake System are not intended to be serviced Individually. Attempting to remove or disconnect certain system components, may result in personal Injury and/or Improper system operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service Precautions > Technician Safety Information > Page 7597 Brake Master Cylinder: Vehicle Damage Warnings Correct Use of Fasteners, and Part Replacement CAUTION: ^ Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. General Motors will call out those fasteners that will require a replacement after removal. General Motors: will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. ^ The use of rubber hoses or parts other than those specified for the Antilock Brake System (ABS) may lead to functional problems requiring replacement of the hydraulic parts. Replace all components included in repair kits used to service this system. Lubricate rubber parts with clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rubber components may result. If any hydraulic component is removed or brake line disconnected, it may be necessary to bleed all or part of the brake system. The fastener tightening specifications listed are for dry, unlubricated fasteners. Chemical Warning CAUTION: Use only DOT 3 brake fluid from a clean, sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5 silicone brake fluid. Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components to deteriorate. Keep all fluid containers capped to prevent contamination. NOTE: Brake fluid will damage painted surfaces. Shop cloths and clean containers should be used to prevent spillage of brake fluid. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > General Description, ABS Brake Master Cylinder: Description and Operation General Description, ABS The hydraulic modulator/master cylinder assembly controls hydraulic pressure to the front calipers and rear wheel cylinders by modulating hydraulic pressure to prevent wheel lock-up. The basic hydraulic modulator configuration consists of gear subassemblies, ball screws, nuts, pistons, and hydraulic check valves. The motor pack consists of three motors, three drive gears, and three Expansion Spring Brake's (ESB)'s. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > General Description, ABS > Page 7600 Brake Master Cylinder: Description and Operation Master Cylinder Description This master cylinder is a composite design (plastic reservoir and aluminum body). This will be used in a diagonally split system (one front and one diagonally opposite rear brake served by the prirnary piston, and opposite front and rear brakes served by the secondary piston). It incorporates the functions of a standard dual master cylinder plus it has a fluid level switch and integral proportioner valves. The proportioner valves are designed to provide better front to rear braking balance during heavy brake application. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 7601 Brake Master Cylinder: Testing and Inspection NOTE: These checks will not determine all master cylinder malfunctions. 1. Check for a cracked master cylinder casting or brake fluid around the master cylinder. Leaks are indicated even if there is only a drop of fluid. A damp condition is not abnormal. 2. Check for a binding pedal linkage. If this is satisfactory, disassemble the master cylinder and check for swollen or elongated primary piston seal(s). If swollen seals are found, substandard or contaminated brake fluid should be suspected. If contaminated, all components should be disassembled and cleaned, all rubber components should be replaced and all pipes flushed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder Brake Master Cylinder: Service and Repair Filling Master Cylinder The master cylinder reservoir must be kept properly filled to ensure adequate reserve and to prevent air and moisture from entering the hydraulic system. However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir must not be overfilled. Do not add fluid if brake hydraulic system is not leaking. The master cylinder reservoir is part of the master cylinder assembly, which is located under the hood on the drivers side of the vehicle. Thoroughiy clean the master cylinder reservoir cover before removal to avoid getting dirt into reservoir. Remove the cover and diaphragm and add fluid as required to bring level to 20 - 26 mm (0.78-1.O inch) below filler neck inside reservoir. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7604 Brake Master Cylinder: Service and Repair Gear Cover (with ABS) Hydraulic Modulator/Master Cylinder Assembly DISASSEMBLE 1. Air cleaner duct clamps and electrical connection. 2. Battery from vehicle. 3. Clip from engine compartment fuse/relay center. 4. Remove air box assembly. 5. Disconnect motor pack electrical connector. 6. Two Torx head screws attaching gear cover. 7. Remove gear cover. ASSEMBLE 1. Gear cover to hydraulic modulator/master cylinder assembly. 2. Torx head screws attaching gear cover. Tighten Torx screws to 4 Nm (36 inch lbs.). 3. Connect motor pack electrical connector. 4. Install air box assembly. 5. Clip to engine compartment fuse/relay center. 6. Battery to vehicle. 7. Air cleaner duct clamps and electrical connections. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7605 Brake Master Cylinder: Service and Repair Gear Replacement (with ABS) CAUTION: The modulator drive gears are under spring load and will turn during disassembly. After removing hydraulic modulator drive gear cover, exercise extreme care not to place fingers into the gear set, since fingers can be pinched by rotating gears. NOTE: Do not attempt to repair damaged motor packs or hydraulic modulators. Other than modulator drive gear replacement, repair of these assemblies is not authorized. Do not lubricate or oil gears or motor pack. DISASSEMBLE 1. Hydraulic modulator/master cylinder assembly. Refer to Hydraulic Modulator/Master Cylinder Assembly 2. Torx head screws attaching gear cover. 3. Four motor pack to hydraulic modulator Torx head screws. Take care in handling the motor pack. If dropped or damaged in the handling, the motor pack must be replaced. 4. Separate motor pack from hydraulic modulator. NOTE: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Turn the modulator gear to position the piston in the center of its travel. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal. 5. Three modulator drive gear to modulator drive shaft retaining nuts. Gear Removal 6. Gears from modulator. ASSEMBLE Gear Positioning NOTE: Do not allow gear to turn while tightening the retaining nut, since the modulator piston can bottom out in the modulator bore damaging the piston. Turn the modulator gear to position the piston in the center of its travel. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear installation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7606 1. Position hydraulic modulator drive gears onto hydraulic modulator drive shaft. 2. Three gear retaining nuts. Tighten Nuts to 8.5 Nm (76 inch lbs.). 3. With the hydraulic modulator upside down, and the gears facing you, rotate each hydraulic modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to the top of the hydraulic modulator bore, simplifying the brake bleeding procedure. 4. Position motor pack onto hydraulic modulator, aligning the three motor pack gears with the modulator gears. Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced. 5. Four motor pack to hydraulic modulator Torx head screws. Tighten Torx head screws to 5 Nm (44 inch lbs.). 6. Gear cover onto hydraulic modulator with Torx head screws. Tighten Torx head screws to 4 Nm (36 inch lbs.). 7. Hydraulic modulator/master cylinder assembly. Refer to Hydraulic Modulator/Master Cylinder Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7607 Brake Master Cylinder: Service and Repair Hydraulic Modulator (with ABS) Hydraulic Modulator/Master Cylinder Assembly DISASSEMBLE 1. Hydraulic modulator/master cylinder assembly. Refer to Hydraulic modulator/master cylinder Assembly. 2. Torx head screws attaching gear cover. 3. Remove gear cover. 4. Four Torx head screws attaching motor pack to hydraulic modulator. 5. Remove motor pack. 6. Two hydraulic modulator to master cylinder banjo bolts, separate hydraulic modulator from master cylinder. 7. Two transfer tubes with O-rings from master cylinder or hydraulic modulator. 8. Banjo bolt O-rings from master cylinder and hydraulic modulator. NOTE: If hydraulic modulator is to be replaced, install the three gears in the same location on replacement hydraulic modulator. Refer to Gear Replacement. No repair of the hydraulic modulator is authorized. Replace as an assembly. Use new transfer tube assemblies when assembling the hydraulic modulator/master cylinder assembly. Make sure two O-rings are properly installed on each transfer tube. ASSEMBLE 1. Two transfer assemblies. Lubricate transfer tube assembly O-rings with clean brake fluid. Install transfer tube assemblies in ports in hydraulic modulator and push in by hand to bottom. 2. Lubricate new banjo bolt O-ring with clean brake fluid and install into the master cylinder and hydraulic modulator. 3. Hydraulic modulator to master cylinder. Clamp mounting flange of master cylinder in a vise. Hold hydraulic modulator and rock into position on master cylinder, inserting transfer tube assemblies into master cylinder ports. 4. Two modulator to master cylinder banjo bolts. Tighten Banjo bolts to 24 Nm (18 ft. lbs.). 5. With the hydraulic modulator upside down, and the gears facing you, rotate each hydraulic modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to the top of the hydraulic modulator bore. 6. Motor pack to hydraulic modulator/master cylinder assembly. 7. Four Torx head screws. Tighten Torx head screws to 5 Nm (44 inch lbs.). 8. Gear cover to hydraulic modulator/master cylinder assembly. Tighten Torx bolts to 4 Nm (36 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7608 Brake Master Cylinder: Service and Repair Filling Master Cylinder The master cylinder reservoir must be kept properly filled to ensure adequate reserve and to prevent air and moisture from entering the hydraulic system. However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir must not be overfilled. Do not add fluid if brake hydraulic system is not leaking. The master cylinder reservoir is part of the master cylinder assembly, which is located under the hood on the drivers side of the vehicle. Thoroughiy clean the master cylinder reservoir cover before removal to avoid getting dirt into reservoir. Remove the cover and diaphragm and add fluid as required to bring level to 20 - 26 mm (0.78-1.O inch) below filler neck inside reservoir. Gear Cover (with ABS) Hydraulic Modulator/Master Cylinder Assembly DISASSEMBLE 1. Air cleaner duct clamps and electrical connection. 2. Battery from vehicle. 3. Clip from engine compartment fuse/relay center. 4. Remove air box assembly. 5. Disconnect motor pack electrical connector. 6. Two Torx head screws attaching gear cover. 7. Remove gear cover. ASSEMBLE 1. Gear cover to hydraulic modulator/master cylinder assembly. 2. Torx head screws attaching gear cover. Tighten Torx screws to 4 Nm (36 inch lbs.). 3. Connect motor pack electrical connector. 4. Install air box assembly. 5. Clip to engine compartment fuse/relay center. 6. Battery to vehicle. 7. Air cleaner duct clamps and electrical connections. Gear Replacement (with ABS) CAUTION: The modulator drive gears are under spring load and will turn during disassembly. After removing hydraulic modulator drive gear cover, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7609 exercise extreme care not to place fingers into the gear set, since fingers can be pinched by rotating gears. NOTE: Do not attempt to repair damaged motor packs or hydraulic modulators. Other than modulator drive gear replacement, repair of these assemblies is not authorized. Do not lubricate or oil gears or motor pack. DISASSEMBLE 1. Hydraulic modulator/master cylinder assembly. Refer to Hydraulic Modulator/Master Cylinder Assembly 2. Torx head screws attaching gear cover. 3. Four motor pack to hydraulic modulator Torx head screws. Take care in handling the motor pack. If dropped or damaged in the handling, the motor pack must be replaced. 4. Separate motor pack from hydraulic modulator. NOTE: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Turn the modulator gear to position the piston in the center of its travel. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal. 5. Three modulator drive gear to modulator drive shaft retaining nuts. Gear Removal 6. Gears from modulator. ASSEMBLE Gear Positioning NOTE: Do not allow gear to turn while tightening the retaining nut, since the modulator piston can bottom out in the modulator bore damaging the piston. Turn the modulator gear to position the piston in the center of its travel. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear installation. 1. Position hydraulic modulator drive gears onto hydraulic modulator drive shaft. 2. Three gear retaining nuts. Tighten Nuts to 8.5 Nm (76 inch lbs.). 3. With the hydraulic modulator upside down, and the gears facing you, rotate each hydraulic modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to the top of the hydraulic modulator bore, simplifying the brake bleeding procedure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7610 4. Position motor pack onto hydraulic modulator, aligning the three motor pack gears with the modulator gears. Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced. 5. Four motor pack to hydraulic modulator Torx head screws. Tighten Torx head screws to 5 Nm (44 inch lbs.). 6. Gear cover onto hydraulic modulator with Torx head screws. Tighten Torx head screws to 4 Nm (36 inch lbs.). 7. Hydraulic modulator/master cylinder assembly. Refer to Hydraulic Modulator/Master Cylinder Assembly Hydraulic Modulator (with ABS) Hydraulic Modulator/Master Cylinder Assembly DISASSEMBLE 1. Hydraulic modulator/master cylinder assembly. Refer to Hydraulic modulator/master cylinder Assembly. 2. Torx head screws attaching gear cover. 3. Remove gear cover. 4. Four Torx head screws attaching motor pack to hydraulic modulator. 5. Remove motor pack. 6. Two hydraulic modulator to master cylinder banjo bolts, separate hydraulic modulator from master cylinder. 7. Two transfer tubes with O-rings from master cylinder or hydraulic modulator. 8. Banjo bolt O-rings from master cylinder and hydraulic modulator. NOTE: If hydraulic modulator is to be replaced, install the three gears in the same location on replacement hydraulic modulator. Refer to Gear Replacement. No repair of the hydraulic modulator is authorized. Replace as an assembly. Use new transfer tube assemblies when assembling the hydraulic modulator/master cylinder assembly. Make sure two O-rings are properly installed on each transfer tube. ASSEMBLE 1. Two transfer assemblies. Lubricate transfer tube assembly O-rings with clean brake fluid. Install transfer tube assemblies in ports in hydraulic modulator and push in by hand to bottom. 2. Lubricate new banjo bolt O-ring with clean brake fluid and install into the master cylinder and hydraulic modulator. 3. Hydraulic modulator to master cylinder. Clamp mounting flange of master cylinder in a vise. Hold hydraulic modulator and rock into position on master cylinder, inserting transfer tube assemblies into master cylinder ports. 4. Two modulator to master cylinder banjo bolts. Tighten Banjo bolts to 24 Nm (18 ft. lbs.). 5. With the hydraulic modulator upside down, and the gears facing you, rotate each hydraulic modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to the top of the hydraulic modulator bore. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7611 6. Motor pack to hydraulic modulator/master cylinder assembly. 7. Four Torx head screws. Tighten Torx head screws to 5 Nm (44 inch lbs.). 8. Gear cover to hydraulic modulator/master cylinder assembly. Tighten Torx bolts to 4 Nm (36 inch lbs.). Hydraulic Modulator Solenoid (with ABS) Hydraulic Modulator Solenoid Removal REMOVE OR DISCONNECT 1. Solenoid electrical connector. 2. Torx head bolts. 3. Solenoid. NOTE: Be sure the seal is still attached to the solenoid when it is removed. If not, check-solenoid bore in modulator. Do not attempt to disassemble solenoid, it is serviceable only as an assembly. Lubricate seal on new solenoid with clean brake fluid. INSTALL OR CONNECT 1. New solenoid. NOTE: Verify that the solenoid lip seal is properly positioned before solenoid is installed in hydraulic modulator. Position solenoid so that its electrical connector will face the same direction as the solenoid that was removed. By hand, press down firmly on solenoid until its flange seats on ABS hydraulic modulator. 2. Torx head bolts. Tighten bolts to 5 Nm (44 inch lbs.). 3. Solenoid electrical connector to solenoid. NOTE: Make sure the solenoid connectors are installed on correct solenoids. It is necessary to bleed hydraulic modulator/master cylinder assembly. Master Cylinder Reservoir DISASSEMBLE 1. Remove master cylinder. 2. Clamp flange of master cylinder body in a vise. NOTE: Do not clamp on master cylinder body. Doing so may damage the master cylinder. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7612 Removing/Installing Spring Pins 3. Spring pins by using a suitable 1/8 inch punch to drive them out. Use care not to damage reservoir or cylinder body when driving out spring pins. 4. Master cylinder reservoir by pulling straight up, away from master cylinder body. 5. Reservoir to body "O"-rings from grooves in master cylinder reservoir and dispose of "O"-rings. Clean reservoir with clean denatured alcohol. Dry with unlubricated compressed air. Inspect master cylinder reservoir for cracks or deformation and replace reservoir if damage is found. ASSEMBLE 1. Lubricate new reservoir to body "O"-rings and reservoir flanges with clean brake fluid. Installing Reservoir 2. Reservoir to body "O"-rings into grooves in master cylinder reservoir. Be sure "O"-rings are properly seated. 3. Master cylinder reservoir to master cylinder body by pressing straight down by hand into master cylinder body. 4. Spring pins by driving in with a 1/8 inch punch using care not to damage reservoir or master cylinder body. 5. Reassemble master cylinder. See: Motor Pack (with ABS) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7613 Hydraulic Modulator/Master Cylinder Assembly DISASSEMBLE 1. Air cleaner duct clamps and electrical connection. 2. Battery from vehicle. 3. Clip from engine compartment fuse/relay center. 4. Remove air box assembly. 5. Disconnect motor pack electrical connector. 6. Two Torx head screws attaching gear cover. 7. Remove gear cover. 8. Four Torx head screws attaching motor pack to hydraulic modulator. 9. Motor pack from hydraulic modulator. NOTE: It is necessary to slightly bend brake pipes out of the way to allow for removal of motor pack. Use care when handling motor pack to ensure motor pack connector is not damaged, or accidental intrusion of brake fluid into the motor pack does not occur. This may result in a premature failure of the motor pack. Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced. If disassembly of the hydraulic modulator/master cylinder assembly was due to an ABS hydraulic functional test that did not pass, the Automated Motor Pack Diagnosis Test should be performed at this time to isolate the motor pack or hydraulic modulator. No repair of the motor pack is authorized. Replace as an assembly. ASSEMBLE 1. Motor pack to hydraulic modulator, reposition brake pipes. Take care in handling the motor pack. If dropped or damaged during handling the motor pack must be replaced. Align each of the three motor pack pinions with the hydraulic modulator gears. 2. Four Torx head screws. Tighten Torx head screws to 5 Nm (44 inch lbs.). 3. Gear cover to hydraulic modulator/master cylinder assembly. 4. Torx head screws attaching gear cover. Tighten Torx bolts to 4 Nm (36 inch lbs.). 5. Connect motor pack electrical connector. 6. Install air box assembly. 7. Clip to engine compartment fuse/relay center. 8. Battery to vehicle. 9. Air cleaner duct clamps and electrical connections. 10. Using the scan tool, perform REHOME procedure. Rebuilding the Master Cylinder Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7614 Compact Master Cylinder Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7615 Removing Master Cylinder Assembly NOTE: Install all new components included in the repair kit used to service this master cylinder. Lubricate rubber parts with clean brake fluid to ease assembly. Do not use lubricated compressed air on brake parts as damage to rubber components may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. The fastener tighetening specificatons are for dry, unlubricated fasteners. Perform service operations on a clean bench, free from all mineral oil materials. DISASSEMBLE NOTE: Master cylinder reservoir cover and reservoir diaphragm can be inspected and/or serviced without removing the master cylinder from the vehicle. 1. Remove master cylinder completely from the vehicle. Refer to Master Cylinder Assembly. 2. Separate modulator assembly from master cylinder assembly. 3. Remove master cylinder reservoir cover and master cylinder reservoir diaphragm. Wipe reservoir cover clean before removing. Empty fluid from reservoir (only if master cylinder is to be completely removed and overhauled). Inspect Master cylinder reservoir cover and diaphragm for cuts, cracks, nicks and deformation. Replace damaged parts. 4. Fluid level switch. 5. Proportioner valve assemblies. 6. Piston retainer while depressing primary piston. Take care not to damage the primary piston, master cylinder bore, or piston retainer groove. 7. Primary piston, secondary piston, secondary piston spring and spring retainer. To remove parts, apply low pressure unlubricated compressed air into upper outlet port at blind end of bore with all other outlet ports plugged. 8. Secondary seal, primary seal and spring retainer from secondary piston. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. No abrasive should be used in bore. Inspect Master cylinder bore for scoring or corrosion. If noted, replace master cylinder. ASSEMBLE 1. Lubricate rubber parts with clean brake fluid to ease assembly. 2. Lubricated secondary seal, primary seal and spring retainer onto secondary piston. 3. Secondary piston spring and secondary piston assembly into cylinder bore. To ease reassembly, lubricate with clean brake fluid. 4. Lubricated primary piston into cylinder bore. 5. Piston retainer (18) while depressing primary piston. 6. Proportioner valve assemblies and fluid level switch. Refer to Proportioner Valves and Fluid Level Switch. 7. Master cylinder reservoir diaphragm into reservoir cover and install on master cylinder reservoir. 8. Master cylinder. Refer to Master Cylinder Assembly. Replacing (with ABS) Hydraulic Modulator/Master Cylinder Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7616 REMOVE OR DISCONNECT 1. Using the scan tool, perform Gear Tension Relief Sequence. 2. Two solenoid electrical connectors. 3. Brake fluid level switch electrical connector. 4. Motor pack electrical connector. 5. Move air cleaner cover and/or intake duct assembly aside. 6. Four brake pipes. Place shop cloth on top of motor pack to catch any dripping fluid. Take care not to allow brake fluid to enter the bottom of the motor pack or the electrical connectors. Plug open lines to prevent fluid loss and contamination. 7. Two nuts attaching hydraulic modulator/master cylinder assembly to vacuum booster. It may be necessary to remove vacuum check valve from vacuum booster to gain access to the nut closest to the check valve. 8. Hydraulic modulator/master cylinder assembly from vehicle. INSTALL OR CONNECT 1. Hydraulic modulator/master cylinder assembly in vehicle. It may be necessary to remove vacuum check valve from vacuum booster to gain access to the nut closet to the check valve. 2. Two nuts attaching hydraulic modulator/master cylinder assembly to vacuum booster. Tighten nuts to 27 Nm (20 ft.lbs.). 3. Four brake pipes to hydraulic modulator/master cylinder assembly. Tighten tube nuts to 24 Nm (18 ft. lbs.). 4. Motor pack electrical connector. 5. Brake fluid level switch electrical connector. 6. Two solenoid electrical connectors. ^ Perform brake bleed. Replacing Master Cylinder Assembly Removing Master Cylinder Assembly NOTE: ^ Install all new components included in the repair kit used to service this master cylinder. ^ Lubricate rubber parts with clean brake fluid to ease assembly. Do not use lubricated compressed air on brake parts as damage to rubber components may result. ^ If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. ^ The fastener tighetening specificatons are for dry, unlubricated fasteners. ^ Perform service operations on a clean bench, free from all mineral oil materials. REMOVE OR DISCONNECT 1. Battery. 2. Air box. 3. Perform gear tension release procedure. See: Antilock Brakes / Traction Control Systems/Testing and Inspection 4. Electrical connector to fluid level switch. 5. Electrical connectors from ABS both solenoids. 6. 3-pin and 6-pin motor pack electrical connectors. 7. Brake pipe tube nuts from master cylinder and modulator assembly. Plug open brake pipes to prevent brake fluid loss and contamination. 8. Master cylinder mounting nuts. 9. Master cylinder and modulator assembly from booster. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Filling Master Cylinder > Page 7617 INSTALL OR CONNECT 1. Master cylinder and modulator assembly to power booster assembly. Tighten master cylinder and modulator assembly mounting nuts to 27 Nm (20 ft. lbs.). 2. Brake pipes tube nuts to master cylinder and modulator assembly. Tighten brake pipe tube nuts to 23 Nm (17 ft. lbs.). 3. Electrical connector to fluid level switch. 4. Electrical connectors from both solenoids. 5. 3-pin and 6-pin motor pack electrical connectors. 6. Fill master cylinder to proper level with clean brake fluid. 7. Bleed hydraulic system. See: Service and Repair 8. Battery. 9. Air box. Reservoir Cap Service REMOVE OR DISCONNECT 1. Thoroughly clean the master cylinder reservoir cap before removal to avoid dirt entering the reservoir. 2. Reservoir cap. 3. Rubber diaphragm from cap. Clean any brake fluid that exits between cap and rubber diaphragm with a dry lint free rag. Inspect brake fluid for proper level. Remove fluid if necessary. INSTALL OR CONNECT 1. Diaphragm into cap. 2. Cap to reservoir. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7622 Wheel Cylinder: Specifications Wheel Cylinder Bore Diameter 0.689 in Wheel Cylinder To Backing Plate 15 ft.lb Wheel Cylinder Bleeder Screw 62 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7623 Anchor Plate Drum Brake Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 7624 Wheel Cylinder Components Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Overhaul Wheel Cylinder: Service and Repair Overhaul Wheel Cylinder Components NOTE: Remove wheel cylinder. Refer to Wheel Cylinder replace. DISASSEMBLE 1. Boots. 2. Pistons and seals. 3. Spring assembly. 4. Bleeder valve. Inspect cylinder bore and pistons for scoring, nicks, corrosion and wear. Use crocus cloth to polish out light corrosion. Replace wheel cylinder assembly if bore will not clean up with crocus cloth. 5. Clean all parts in clean denatured alcohol. Dry parts with unlubricated compressed air. Lubricate new seals with clean brake fluid. ASSEMBLE 1. Bleeder valve. Tighten bleeder valve to 7 Nm (62 inch lbs.). 2. Spring assembly. 3. Seals, pistons and boots. 4. Install wheel cylinder to vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Overhaul > Page 7627 Wheel Cylinder: Service and Repair Replace Anchor Plate Drum Brake Assembly NOTE: Clean dirt and foreign material around wheel cylinder assembly inlet and pilot. REMOVE OR DISCONNECT 1. Inlet tube nut and line. Plug opening in line to prevent fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Overhaul > Page 7628 2. Brake drum. 3. Hub and bearing assembly. 4. Pull backing plate away from axle flange. Do not let backing plate hang from parking brake cable. Damage may occur. 5. Wheel cylinder bolts using a #6 Torx socket. 6. Wheel cylinder. Wheel Cylinder Components INSTALL OR CONNECT 1. Wheel cylinder bolts using a #6 Torx socket. Tighten wheel cylinder bolts to 20 Nm (15 ft. lbs.). 2. Backing plate to axle flange. 3. Hub and bearing assembly. 4. Brake drum. 5. Inlet tube line and nut. Tighten inlet tube nut to 23 Nm (17 ft. lbs.). 6. Bleed wheel cylinder. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 73-50-18 > Jan > 98 > Brakes Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 73-50-18 > Jan > 98 > Brakes Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7638 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 73-50-18 > Jan > 98 > Brakes Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7639 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7645 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7646 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Page 7647 Parking Brake Cable Routing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable Parking Brake Cable: Service and Repair Front Parking Brake Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 7650 Parking Brake Cable Routing REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Pull and hold cable towards the rear of the vehicle to create slack in cable. 3. Bend tang on connector to allow cable removal. 4. Cable from connector. 5. Fold over retaining clip. 6. Cable from equalizer. 7. Lower vehicle. 8. Console. 9. Move lever to off position. 10. Cable conduit end fitting from lever assembly. 11. Pull cable until notch on ratchet is visible through cover plate opening. 12. Push pawl spring downward toward notch in ratchet. 13. Release cable slowly to allow notch to catch leg of spring. 14. Front parking brake cable button from reel assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 7651 15. Remove left rocker panel/door sill plate. 16. Grommet and retainer from floor pan. 17. Cable from clip (#2), under carpet. 18. Front cable. INSTALL OR CONNECT 1. Cable through floor pan, from interior to exterior. 2. Cable conduit fitting to lever assembly. 3. Front parking brake cable button to reel assembly. 4. Cable into clip (#2), (under carpet). 5. Console. 6. Left rocker panel/door sill plate. 7. Raise vehicle. 8. Fold over bracket to body. 9. Cable to equalizer assembly. 10. Cable to connector. 11. Bend tang on connector to retain cable. 12. Lower vehicle. 13. Fully apply and release hand brake 4-6 times to activate self adjust system. CAUTION: This is a self adjusting system and damage may result from attempting to adjust or modify this system in any way. It may be necessary to adjust rear brakes to obtain the proper tension in the system Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 7652 Parking Brake Cable: Service and Repair Rear Parking Brake Cables Parking Brake Cables And Lever Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 7653 Parking Brake Cable Routing REMOVE OR DISCONNECT 1. Console. 2. Move lever to off position. 3. Cable conduit fitting from lever assembly. 4. Pull cable until notch on ratchet is visible through cover plate opening. 5. Push pawl spring downward toward notch in ratchet. 6. Release cable slowly to allow notch to catch leg of spring. 7. Raise vehicle and suitably support. 8. Bend tang on connector to allow cable removal. 9. Pull and hold cable towards the rear of the vehicle to create slack in cable. 10. On right rear cable, remove from connector, on left rear remove from equalizer. 11. Brake drum. 12. Tire and wheel assembly. 13. Insert screwdriver between brake shoe and lower part rear park brake lever. 14. Cable eyelet fitting from rear park brake lever. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 7654 15. Conduit fitting from backing plate while depressing conduit fitting retaining tangs. INSTALL OR CONNECT 1. Conduit fitting into backing plate. 2. Parking brake cable to parking brake lever in drum assembly. 3. Tire and wheel assembly. 4. Brake drum. 5. Conduit fitting into axle bracket. 6. Cable to equalizer (left rear). 7. Cable to connector (right rear). 8. Lower vehicle. 9. Console. 10. Fully apply and release hand brake 4-6 times to self adjust system. 11. Check parking brake tension. See: Adjustments CAUTION: This is a self adjusting system and damage may result from attempting to adjust or modify this system in any way. It may be necessary to adjust rear brakes to obtain the proper tension in the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Diagrams Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Diagrams > Page 7658 Parking Brake Lever: Service and Repair Parking Brake Cables And Lever Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Diagrams > Page 7659 Parking Brake Cable Routing REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Pull and hold cable towards the rear of the vehicle to create slack in cable. 3. Bend tang on connector to allow cable removal. 4. Cable from connector. 5. Lower vehicle. 6. Console. 7. Move lever to off position. 8. Cable conduit end fitting from lever assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Diagrams > Page 7660 Self Adjust Lockout 9. Pull cable until notch on ratchet is visible through cover plate opening. 10. Push pawl spring downward toward notch in ratchet. 11. Release cable slowly to allow notch to catch leg of spring. 12. Front parking brake cable button from reel assembly. 13. Electrical connector. 14. Nuts securing lever. 15. Lever. INSTALL OR CONNECT 1. Insure Pawl spring is engaged as described in steps 9-11 in above removal procedure. 2. Front parking brake cable to lever assembly and secure cable conduit fittings into lever assembly. Tighten Parking brake lever nuts to 25 Nm (18 ft. lbs.). 3. Parking brake lever and attaching nuts. 4. Electrical connector. 5. Raise vehicle and suitably support. 6. Cable to connector. 7. Lower vehicle. 8. Fully apply and release hand brake 4-6 times to activate self adjust system. 9. Console. NOTE: Parking brake adjustment is not necessary. This is a self adjusting system and damage may result from attempting to adjust or modify this system in any way. It may be necessary to adjust rear brakes to obtain the proper tension in the system Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7669 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7670 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 03-07-30-021A > Nov > 03 > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 03-07-30-021A > Nov > 03 > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7680 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 03-07-30-021A > Nov > 03 > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7681 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 71-65-37 > May > 97 > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 71-65-37 > May > 97 > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7692 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 71-65-37 > May > 97 > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7693 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 71-65-37 > May > 97 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 71-65-37 > May > 97 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7699 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 71-65-37 > May > 97 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7700 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > Page 7701 Crankshaft Position Sensor: Locations RH Front Of Engine And Cooling Fan Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7710 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7711 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7717 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7718 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Page 7719 LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Mounting Nuts ..................................................................................................................................... ..................................................... 27 Nm (20 ft. lbs.) Pedal Attaching Nuts ....................................... ......................................................................................................................................... 27 Nm (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 7724 Vacuum Brake Booster: Locations Vacuum Booster Hose Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service Precautions > Technician Safety Information Vacuum Brake Booster: Technician Safety Information NOTE: Do not use lubricated compressed air on brake parts as damage to rubber parts may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. The torque values specified are for dry, unlubricated fasteners. Perform service operations on a clean bench free from all mineral oil materials. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service Precautions > Technician Safety Information > Page 7727 Vacuum Brake Booster: Vehicle Damage Warnings CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant. Unless otherwise specified, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service Precautions > Page 7728 Vacuum Brake Booster: Description and Operation This booster is a tandem vacuum suspended unit. In a normal operating mode, with the service brakes in the released position, the tandem vacuum suspended booster operates with vacuum on both sides of its diaphragms. When the brakes are applied, air at atmospheric pressure is admitted to one side of each diaphragm to provide the power assist. When the service brake is released, the atmospheric air is shut off from the one side of each diaphragm. The air is then drawn from the booster through the vacuum check valve to the vacuum source. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service Precautions > Page 7729 Vacuum Brake Booster: Testing and Inspection Power Brake Diagnosis: Power Brake Unit Trouble Diagnosis Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Replace Exterior Components Vacuum Brake Booster: Service and Repair Replace Exterior Components Exterior Components NOTE: Vacuum check valve and grommet can be inspected and/or serviced without removing the booster from the vehicle. REMOVE OR DISCONNECT 1. Vacuum check valve and grommet. 2. Booster. See: Replace Power Booster 3. Boot and air filter. 4. Front insulator. Inspect boot, front housing seal, and grommet forcuts, nicks and excessive wear. Replace part(s) if any of the above are found. Clean above parts in clean denatured alcohol. Dry with unlubricated compressed air. NOTE: Lubricate inside and outside diameters of grommet and front housing seal with a thin layer of silicone grease. INSTALL OR CONNECT 1. Front insulator. 2. Air filter and boot. 3. Booster. See: Replace Power Booster 4. Grommet and vacuum check valve. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Replace Exterior Components > Page 7732 Vacuum Brake Booster: Service and Repair Replace Power Booster Power Booster NOTE: It is not necessary to remove or disconnect master cylinder from the vehicle in order to remove the vacuum booster. However, if both the vacuum booster and master cylinder are to be removed, remove the master cylinder first. REMOVE OR DISCONNECT 1. Battery. 2. Air box. 3. Master cylinder attaching nuts. 4. Master cylinder from booster. Move master cylinder forward just enough to clear studs on the vacuum booster. This will flex the brake pipes slightly, take care not to bend or distort the brake pipes. Be careful not to lose or dislodge the insulator between the booster and the front of dash. 5. Vacuum hose from vacuum check valve. 6. Booster attaching nuts. 7. Booster pushrod from brake pedal. Tilt entire vacuum booster slightly to work booster pushrod off pedal clevis pin without putting undue side pressure on the pushrod. 8. Booster from vehicle. INSTALL OR CONNECT 1. Booster into vehicle. 2. Booster pushrod to brake pedal. Tilt entire vacuum booster slightly to work booster pushrod onto pedal clevis pin without putting undue side pressure on the pushrod. Use left hand to align pushrod with pedal and push together. 3. Booster attaching nuts. Tighten booster to brake pedal attaching nuts to 27 Nm (20 ft. lbs.). 4. Booster vacuum hose to vacuum check valve. 5. Master cylinder to booster and attaching nuts. 6. Air box. 7. Battery.Tighten master cylinder to booster attaching nuts to 27 Nm (20 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations > Page 7737 Electronic Brake Control Relay: Description and Operation The Electronic Brake Control Relay is a normally-open contact type, and has special contact material to handle the high currents required for ABS VI operation. The relay allows the battery voltage and current to be supplied to the EBCM, which supplies power to the motors and solenoids. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Relay <--> [ABS Main Relay] > Component Information > Locations > Page 7738 Electronic Brake Control Relay: Service and Repair REMOVE OR DISCONNECT 1. Nut attaching Electronic Brake Control Relay. 2. Electronic Brake Control Relay. INSTALL OR CONNECT 1. Electronic Brake Control Relay. 2. Nut attaching Electronic Brake Control Relay. Tighten nut to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: Customer Interest Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7747 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7748 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7754 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 7755 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBCM EBCM Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBCM > Page 7758 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 Electronic Brake Control Module: Diagrams C1 Electronic Brake Control Module (EBCM): C1 Electronic Brake Control Module (EBCM)l: C1 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 7761 Electronic Brake Control Module: Diagrams C2 Electronic Brake Control Module (EBCM)l: C2 Electronic Brake Control Module (EBCM)l: C2 (Part 1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > C1 > Page 7762 Electronic Brake Control Module (EBCM)l: C2 (Part 2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 7763 Electronic Brake Control Module: Description and Operation CONTROLS, INPUTS AND OUTPUTS The controlling element of ABS VI is a microprocessor based Electronic Brake Control Module (EBCM). Inputs to the system include four wheel speed sensors, the brake switch, the brake fluid level switch, ignition switch, and unswitched battery voltage. Outputs include three bi-directional motor controls, two solenoid controls and the Electronic Brake Control Relay. A serial data line is used for service diagnostic tools (Scan Tool), assembly plant testing and control of indicator lamps in the IPC. OPERATION The EBCM monitors the speed of each wheel. If any wheel begins to approach lock-up, the EBCM controls the motors and solenoids to reduce brake pressure to the wheel approaching lock-up. Once the wheel regains traction, brake pressure is increased until the wheel again begins to approach lock-up. This cycle repeats until either the vehicle comes to a stop, the brake is released, or no wheels approach lock-up. With ETS, the EBCM monitors the wheel spin slip through the front wheel speed sensors. If either of the front wheels begins to slip, the EBCM determines the desired wheel torque needed to minimize front wheel spin. This information is sent to the Powertrain Control Module (PCM) via the serial data link. The PCM then calculates a spark retard value to achieve the requested torque and upshifts the transmission if needed. DIAGNOSTICS The EBCM monitors itself, each input and each output for proper operation. If any system malfunction is detected, the EBCM will store a DTC in nonvolatile memory (DTCs will not disappear if the battery is disconnected). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 7764 Electronic Brake Control Module: Service and Repair EBCM Removal REMOVE OR DISCONNECT 1. Dash wiring harness connectors from EBCM. 2. EBCM from bracket. INSTALL OR CONNECT 1. EBCM to bracket 2. Dash wiring harness connectors to EBCM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations Fluid Level Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations > Page 7770 LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7771 Brake Fluid Level Sensor/Switch: Description and Operation The master cylinder is equipped with a fluid level switch located in the side of the master cylinder reservoir. This switch will activate the red "BRAKE" light if a low fluid condition is detected. Once the fluid level is corrected the "BRAKE" light will go out. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7772 Brake Fluid Level Sensor/Switch: Service and Repair Fluid Level Switch REMOVE OR DISCONNECT 1. Electrical connector from fluid level switch. Proportioner Valves 2. Fluid level switch using needle nose pliers to compress switch locking tabs at inboard side of master cylinder reservoir. INSTALL OR CONNECT 1. Fluid level switch into master cylinder reservoir until locking tabs snap in place. 2. Electrical connector to fluid level switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7781 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7782 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7788 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 7789 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Page 7790 LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations Center Passenger Compartment, Above Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 7795 LH I/P And Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set Wheel Speed Sensor: Customer Interest ABS Indicator Lamp On, DTC 21,22,32 or 33 Set File In Section: 5 - Brakes Bulletin No.: 63-50-15B Date: March, 1998 Subject: ABS Indicator Lamp ON, DTC 21, 22, 32 or 33 Set (Install Front ABS Wheel Speed Sensor Wiring Harness Connector Kit) Models: 1992-97 Buick Skylark 1991-96 Chevrolet Beretta, Corsica 1992-97 Chevrolet Cavalier 1992-97 Oldsmobile Achieva 1992-94 Pontiac Sunbird 1995-97 Pontiac Sunfire 1992-97 Pontiac Grand Am This bulletin is being revised to update parts and applicable model information. Please discard Corporate Bulletin Number 63-50-15A - (Section 5 - Brakes) Condition Some owners may comment that the ABS indicator lamp is "ON". Also, malfunction DTC 21, 22, 32 or 33 could set. Cause The right front and left front ABS wheel speed sensor wiring harness could be damaged and result in an open circuit. The wiring harness may be damaged approximately 4 inches (10 cm) back from the harness connector to the wheel speed sensor. This allows moisture to enter the harness causing corrosion and resulting in the open circuit. Correction A thorough inspection for corrosion and/or damage should be performed on suspect vehicles. It may be necessary to move the protective conduit away in order to inspect the wiring properly. If a failure occurs and damage is found, install the front ABS wheel speed sensor wiring harness connector kit(s). The kit includes instructions, splices, and "pigtail" connector. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set > Page 7804 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time H2530 Right Side Use published H2531 Left Side Labor Operation Time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set Wheel Speed Sensor: All Technical Service Bulletins ABS Indicator Lamp On, DTC 21,22,32 or 33 Set File In Section: 5 - Brakes Bulletin No.: 63-50-15B Date: March, 1998 Subject: ABS Indicator Lamp ON, DTC 21, 22, 32 or 33 Set (Install Front ABS Wheel Speed Sensor Wiring Harness Connector Kit) Models: 1992-97 Buick Skylark 1991-96 Chevrolet Beretta, Corsica 1992-97 Chevrolet Cavalier 1992-97 Oldsmobile Achieva 1992-94 Pontiac Sunbird 1995-97 Pontiac Sunfire 1992-97 Pontiac Grand Am This bulletin is being revised to update parts and applicable model information. Please discard Corporate Bulletin Number 63-50-15A - (Section 5 - Brakes) Condition Some owners may comment that the ABS indicator lamp is "ON". Also, malfunction DTC 21, 22, 32 or 33 could set. Cause The right front and left front ABS wheel speed sensor wiring harness could be damaged and result in an open circuit. The wiring harness may be damaged approximately 4 inches (10 cm) back from the harness connector to the wheel speed sensor. This allows moisture to enter the harness causing corrosion and resulting in the open circuit. Correction A thorough inspection for corrosion and/or damage should be performed on suspect vehicles. It may be necessary to move the protective conduit away in order to inspect the wiring properly. If a failure occurs and damage is found, install the front ABS wheel speed sensor wiring harness connector kit(s). The kit includes instructions, splices, and "pigtail" connector. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 63-50-15B > Mar > 98 > ABS Indicator Lamp On, DTC 21,22,32 or 33 Set > Page 7810 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time H2530 Right Side Use published H2531 Left Side Labor Operation Time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 7811 Wheel Speed Sensor: Specifications Front Wheel Sensor Bolt 107 in.lb Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead LH Front Wheel (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7814 LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7815 Front Wheel Speed Sensor Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7816 LH Front Wheel (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > A.B.S. Wheel Speed Sensor Lead > Page 7817 Rear Axle Harness Removal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service Precautions > Technician Safety Information Wheel Speed Sensor: Technician Safety Information WARNING: Raise and support vehicle on suitable hoist . Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service Precautions > Technician Safety Information > Page 7820 Wheel Speed Sensor: Vehicle Damage Warnings CAUTION: ^ The front wheel speed sensor wiring is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. ^ The front wheel speed sensor wiring is not repairable in the control arm section of the wiring harness. This section of the wiring harness must be replaced with the appropriate wiring harness service kit "pigtail." The splice must be located within the main branch of the engine harness. Do not attempt to solder, splice, or crimp this section of the wiring harnesses as eventual failure will likely result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring Wheel Speed Sensor: Description and Operation Toothed Ring The toothed ring mentioned above is pressed onto the outer Constant Velocity (CV) joint. Each ring contains 48 equally spaced teeth. Care should be exercised during service procedures to avoid contact with this ring, as damage to one or more teeth may result. If the ring is damaged, the outer CV joint must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7823 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensors The front wheel speed sensors are of a variable reluctance type. Each sensor is attached to the knuckle assembly in close proximity to a toothed ring. An AC voltage is generated when the toothed ring passes by the sensor. The magnitude and frequency are proportional to the speed of the wheel and both will increase with increasing speed. The sensor is not repairable, nor is the air gap adjustable. However, air gap should be between 0.5 mm (0.020 inches) and 1.7 mm (0.070 inches). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7824 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Wiring The front wheel speed sensor wiring is constructed of highly flexible twisted pair wiring. This wiring exists because the front wheel speed sensor wiring circuits must connect to the suspension of the vehicle, thus the wiring in this area is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. For this reason, THE FRONT WHEEL SPEED SENSOR WIRING IS NOT REPAIRABLE IN THE CONTROL ARM SECTION OF THE WIRING HARNESS. THIS SECTION OF THE WIRING HARNESS MUST BE REPLACED WITH THE APPROPRIATE WIRING HARNESS SERVICE KIT "PIGTAIL." DO NOT ATTEMPT TO SOLDER, SPLICE, OR CRIMP THIS SECTION OF THE WIRING HARNESSES AS EVENTUAL FAILURE WILL LIKELY RESULT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7825 Wheel Speed Sensor: Description and Operation Rear Wheel Speed Sensors and Rings The rear wheel speed sensors operate in the same manner as the front wheel speed sensors. Refer to Front Wheel Speed Sensors. The wheel speed sensor and toothed ring are contained within the dust cap of the integral rear wheel bearing. This allows for improved environmental protection and easier assembly. The sensor and toothed ring are not repairable and no provision for air gap adjustment exists. If a rear wheel speed sensor fails, the entire integral bearing and speed sensor assembly must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Toothed Ring > Page 7826 Wheel Speed Sensor: Description and Operation Rear Axle Harness The rear axle harness is constructed of twisted pair wiring. Because the rear axle harness is not subjected to the same motion as the front wheel speed sensor wiring, the rear axle harness can be serviced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Front Wheel Speed Sensor Removal REMOVE OR DISCONNECT 1. Raise and support vehicle on suitable hoist. 2. Front sensor electrical connector. 3. Retaining bolt. 4. Front wheel speed sensor. If sensor will not slide out of knuckle, remove brake rotor and use a blunt punch or equivalent tool to push sensor from back side of knuckle. If sensor locating pin breaks off and remains in knuckle during removal, proceed as follows. a. Remove brake rotor and remove broken pin using a blunt punch. b. Clean hole using sand paper wrapped around a screwdriver or other suitable tool. Never attempt to enlarge the hole. INSTALL OR CONNECT 1. Front wheel speed sensor on mounting bracket. Make sure front wheel speed sensor is properly aligned and lays flat against bosses on knuckle. 2. Retaining bolt. Tighten retaining bolt to 12 Nm (107 inch lbs.). 3. Front sensor electrical connector to front wheel speed sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7829 Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Wiring Right Front Wheel Speed Sensor Harness Left Front Wheel Speed Sensor Harness CAUTION: ^ The front wheel speed sensor wiring is subjected to the same motion as a spring or shock absorber. Consequently, any repair to the front wheel speed sensor wiring circuits in the control arm section of the wiring harness will result in stiffening and eventual failure due to wire fatigue. ^ The front wheel speed sensor wiring is not repairable in the control arm section of the wiring harness. This section of the wiring harness must be replaced with the appropriate wiring harness service kit "pigtail." The splice must be located within the main branch of the engine harness. Do not attempt to solder, splice, or crimp this section of the wiring harnesses as eventual failure will likely result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7830 REMOVE OR DISCONNECT 1. Connector from wheel speed sensor. 2. Harness attaching clips for control arm and splash shield. 3. Lower vehicle. 4. Harness attaching clips from strut tower. 5. Cut wheel speed sensor wiring circuits within main engine harness. 6. Strip insulation on engine harness leads and new wheel speed sensor harness leads. INSTALL OR CONNECT 1. Splice sleeve provided in jumper harness kit over each engine harness leads. 2. New wheel speed sensor harness leads to engine harness leads (matching color) and crimp connections. 3. Heat shrink tube lightly to seal. 4. Harness attaching clip to strut tower. 5. Raise and support vehicle on suitable hoist. 6. Harness attaching clips to control arm and splash shield. 7. Connector to wheel speed sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7831 Wheel Speed Sensor: Service and Repair Rear Axle Harness Rear Axle Harness Removal WARNING: Raise and support vehicle on suitable hoist. REMOVE OR DISCONNECT 1. Two rear sensor electrical connectors from rear wheel bearing and speed sensor assemblies. 2. Rear axle harness electrical connector from body to ABS and fuel sender connector. 3. Wire harness from restraints. 4. Rear speed sensor wiring harness from vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor > Page 7832 INSTALL OR CONNECT 1. Rear speed sensor wiring harness in vehicle. 2. Wire harness restraints. 3. Rear ABS axle harness electrical connector to body to ABS and fuel sender connector. 4. Two rear sensor electrical connectors to rear wheel bearing and speed sensor assemblies. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 7838 Clutch Switch: Service and Repair REMOVE OR DISCONNECT 1. Wire harness connector from clutch pedal position switch. 2. Clutch pedal position switch from clutch pedal assembly. INSTALL OR CONNECT 1. Clutch pedal position switch to clutch pedal assembly. 2. Wire harness connector to clutch pedal position switch. 3. Verify proper operation of switch. The starter should engage only when clutch is fully disengaged. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7848 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7849 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7850 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7860 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7861 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7862 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 7868 Ignition Switch Lock Cylinder: Service and Repair Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations LH Engine/Transaxle LH Front Of Engine/Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 Neutral Safety Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Locations LD9 Negative Battery Cable To Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Technical Service Bulletins > Customer Interest for Battery Cable, Positive: > 83-64-16 > Jun > 98 > Battery Weak, Discharged/Slow Starting/GEN or MIL On Positive: Customer Interest Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Technical Service Bulletins > All Technical Service Bulletins for Battery Cable, Positive: > 83-64-16 > Jun > 98 > Battery - Weak, Discharged/Slow Starting/GEN or MIL On Positive: All Technical Service Bulletins Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis Alternator: Technical Service Bulletins Tools - Released for CS Generator Diagnosis File In Section: 6 - Engine Bulletin No.: 83-64-09 Date: March, 1998 INFORMATION Subject: New Tool J 41450-B, Released for CS Generator Diagnosis Models: 1988-98 Passenger Cars and Light Trucks with CS-Series Generators A new CS-Series Generator Tester, J 41450-B, has been sent to all dealers as part of the Essential Tool Package. This tool will work on all CS-Series generators for past model years. The tool is shown in Figure 1. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 7928 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 7929 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 7930 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 7931 Generator Not Operating Properly The charts shown can be used in place of the diagnostic procedures in previous Service Manuals when this new tool is used. This information will be included in the 1999 Service Manual. Inspect the following before testing the generator: ^ The battery. Make sure the vehicle battery is in good condition and fully charged. Refer to Battery Load Test. ^ The built in hydrometer in the battery. The green eye must be showing in the hydrometer. ^ The voltage across the battery terminals with all the loads OFF should be above 12 V. Refer to Battery Load Test. ^ Make sure the battery connections are clean and tight. ^ The drive belt for damage or looseness. ^ The wiring harness at the generator. Make sure the harness connector is tight and latched. Make sure the output terminal of the generator is connected to the vehicle battery (positive) generator lead. ^ All the charging system related fuses and electrical connections for damage or looseness. Refer to the starter and charging system schematics. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 7932 Alternator: Technical Service Bulletins Engine Controls - Revised Table PCM Controlled Generator File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-65 Date: September, 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Engine Controls - Revised PCM Controlled Generator Table Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin revises the PCM Controlled Generator Table for the following service manuals: ^ 1997 GMP/97-N-2 Page 6E-287 ^ 1997 GMP/97-J-2 Pages 6E-300 and 6E-706 ^ 1998 GMP/98-N-3 Pages 6-766 ^ 1998 GMP/96-J-3 Pages 6-751 and 6-1172 In the PCM Controlled Generator Table, Step 8 refers to GEN F in the Action column. The parameter should be Generator PWM. Please update your service manual with this revision. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Amperage Alternator: Specifications Amperage Model ................................................................................................................................................... ..................................................................... CS130D Rated Output ................................................... .............................................................................................................................................................. . 105A Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Amperage > Page 7935 Alternator: Specifications Charging Voltage 13.0-16.0 Volts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Fusible Link G to Generator Lower Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Fusible Link G to Generator > Page 7938 Alternator: Locations Generator Front Right Of Engine RH Front Of Engine And Cooling Fan Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Fusible Link G to Generator > Page 7939 LH Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations > Fusible Link G to Generator > Page 7940 RH Front Of Engine And Cooling Fan Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 Alternator: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7969 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7970 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7971 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7972 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7973 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7974 Generator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 7975 Alternator: Description and Operation The generator does not require periodic lubrication. The rotor shaft is mounted on bearings. Each bearing contains a permanent grease supply. At periodic intervals, check the mounting bolts for tightness and the drive belt for tension. The drive belt is self-adjusting within tensioner operating limits. Service the CS-13OD generator as a complete unit. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > On-Vehicle Service Alternator: Service and Repair On-Vehicle Service Generator Mounting REMOVE OR DISCONNECT 1. Negative battery cable at battery. 2. Serpentine belt. CAUTION: To avoid personal injury when rotating the serpentine belt tensioner on 2.4L use a tight fitting 13 mm wrench that is at least 61 cm (24") long. This operation can be done using tool J 37059 or equivalent. 3. Generator mounting stud and bolts. 4. Generator electrical connections. 5. Generator assembly. INSTALL OR CONNECT 1. Generator assembly. 2. Generator electrical connections. 3. Generator mounting stud and bolts. 4. Serpentine belt. 5. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > On-Vehicle Service > Page 7978 Alternator: Service and Repair Unit Repair The CS-13OD generator is serviced as a complete assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 7983 Clutch Switch: Service and Repair REMOVE OR DISCONNECT 1. Wire harness connector from clutch pedal position switch. 2. Clutch pedal position switch from clutch pedal assembly. INSTALL OR CONNECT 1. Clutch pedal position switch to clutch pedal assembly. 2. Wire harness connector to clutch pedal position switch. 3. Verify proper operation of switch. The starter should engage only when clutch is fully disengaged. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7993 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7994 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 7995 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder Technical Service Bulletin # 73-01-09 Date: 971001 Starting - Revised Procedures for Inop Ignition Cylinder File In Section: 0 - General Information Bulletin No.: 73-01-09 Date: October, 1997 INFORMATION Subject: New Tumblers for Cylinder Recoding, Revised Repair Procedures for Inoperative Ignition Cylinders (Seized/Won't Rotate), Labor Operation/Time Allowances Models: 1995-97 Buick Skylark, Riviera 1995-97 Chevrolet Cavalier 1997 Chevrolet Corvette, Malibu, Venture 1995-97 Oldsmobile Achieva 1997 Oldsmobile Aurora, Cutlass, Silhouette 1995-97 Pontiac Grand Am, Sunfire 1997 Pontiac Grand Prix, Trans Sport 1995-97 Chevrolet and GMC C/K, S/T Models 1996-97 Chevrolet and GMC G, M/L Vans 1996-97 Oldsmobile Bravada The information in this bulletin concerns new designed tumblers for recoding lock cylinders that use double sided reversible keys, revised procedures for servicing ignition lock cylinders that are seized or not able to rotate and revised labor time guide information and allowances. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 8005 The existing labor operation (E7200) has been changed to include "Add" conditions for cylinders that will not rotate. New Tumblers New tumblers are available from GMSPO for recoding lock cylinders that use double-sided reversible keys. These new tumblers should be used immediately and information about the disposition of original tumblers will be provided by GMSPO. Figure 1 shows the new tumbler profile. The shaded area was part of the original tumbler profile, and is removed on the new tumblers. The new part numbers for the tumblers are as follows: Part No. 2852732 = Tumbler # 1 Part No. 2852733 = Tumbler # 2 Part No. 2852734 = Tumbler # 3 Part No. 2852735 = Tumbler # 4 Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. New Procedures For Seized/Won't Rotate Column Mounted Ign. CYL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 8006 A. On G, J and N Models: DO NOT REMOVE THE STEERING COLUMN as indicated in the Service Manual procedure. 1. Remove the tilt lever, upper and lower column covers. 2. Drill hole in module housing as indicated in the illustration using a short drill bit (1/8" followed by 9/32") and 90 degree drill motor or go degree drill attachment to break or access the retaining spring for the lock cylinder button, see Figure 2. 3. Using a pick or needle nose pliers, remove the retaining spring from the hole. 4. Using pliers, grasp and remove the retaining button for the cylinder. 5. Remove the cylinder from the housing. 6. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 7. Install the new cylinder and reinstall the steering column components. B. On U, W, and light duty trucks, follow the Service Manual procedure for keys missing, or cylinders won't rotate. Procedure: Instrument Panel Mounted Switches Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 73-01-09 > Oct > 97 > Starting - Revised Procedures for Inop Ignition Cylinder > Page 8007 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 01-02-35-010 > Nov > 01 > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 01-02-35-010 Date: November, 2001 SERVICE MANUAL UPDATE Subject: Revised Lock Cylinder Replacement Models: 1995-2001 Chevrolet Cavalier 1995-2001 Pontiac Sunfire This bulletin is being issued to revise the Lock Cylinder Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following information was omitted from the Service Manual: If you replace the ignition lock cylinder, the system will enter the long tamper mode. If the system enters the long tamper mode, ensure that the system completes a long tamper mode cycle. During the long tamper mode cycle, the THEFT indicator will flash for the full 10 minutes. The instrument cluster and the PCM require the full 10 minutes in order to complete the learn cycle. Ensure that the ignition switch remains in RUN until the indicator stops flashing. If you turn the ignition switch before the indicator stops flashing, ensure that you repeat the long tamper cycle from the beginning. Important: Due to component variability, the vehicle theft deterrent (VTD) system must have the learn procedure performed regardless, even if the vehicle starts on the first ignition cycle after a VTD repair. All codes in the theft deterrent module must be cleared for a relearn. DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 8013 Ignition Switch Lock Cylinder: Service and Repair Important: This new procedure involves drilling a hole through the plastic ignition switch and into the lock cylinder slightly to break or access a cylinder release button retaining spring (similar to G, J and N models). The removal of the broken spring and then the release button will allow the switch to be reused. 1. Remove the necessary trim panels to gain access to the instrument panel mounted switch (refer to information in "Body and Accessories Section, Instrument Panel, Gauges and Consoles"). a. On instrument panel mounted N models (Malibu and Cutlass), the switch and cylinder can be accessed after removing the instrument cluster assembly and positioning the switch/cylinder upward in the cavity for the cluster assembly. b. On Corvette models, the switch and cylinder can be accessed after removing the knee bolster from the lower instrument panel area and positioning the switch/cylinder downward from its location on the instrument panel. 2. Loosen switch from instrument panel and disconnect the electrical connections, BUT NOT the cable connection for BTSI (Brake/Transmission Shift Interlock). 3. Protect the immediate work area with a fender cover or other suitable material. 4. Locate the surface for the cylinder release button on the plastic ignition switch housing and center punch a location on the "rib" approximately 3/8" rearward (toward the key entry end) from the cylinder release button, see Figure 3. 5. Using a 1/8" drill bit, carefully drill a pilot hole through the plastic housing only. 6. Using a 9/32" drill bit, carefully drill a larger hole at the pilot location, and slightly into the lock cylinder surface to break the release button retaining spring. 7. Remove portions of the broken spring from the hole using a small pair of needle nose pliers (or other suitable tool) and turn switch over to shake out the release button. 8. Grasp the lock cylinder, remove it from the switch housing. 9. Remove any plastic "flash" from the drilling operations and, using compressed air, blow out the ignition switch assembly. 10. Follow the procedures in the General Information Section of the appropriate vehicle Service Manual when recoding of cylinders is required. 11. Install the new cylinder(s) as required by rotating both the cylinder and ignition switch to the "ON" position and pushing the cylinder into the switch. It may be necessary to depress the release button slightly as it passes by the 9/32" hole previously drilled in the housing. 12. Reassemble the ignition switch and instrument panel components as indicated by the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8018 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8019 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8020 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations LH Engine/Transaxle LH Front Of Engine/Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Neutral Safety Switch: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8049 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8050 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8051 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8052 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8053 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8054 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8055 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8056 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 83-64-16 > Jun > 98 > Battery - Weak, Discharged/Slow Starting/GEN or MIL On Starter Motor: Customer Interest Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 83-64-16 > Jun > 98 > Battery - Weak, Discharged/Slow Starting/GEN or MIL On Starter Motor: All Technical Service Bulletins Battery - Weak, Discharged/Slow Starting/GEN or MIL On File In Section: 6 - Engine Bulletin No.: 83-64-16 Date: June, 1998 Subject: Weak or Discharged Battery, Slow Starting, GEN or MIL Lamp On, Various Driveability Symptoms (Repair B+ Stud and/or Wiring on Starter) Models: 1997-98 Buick Skylark 1997-98 Chevrolet Cavalier, Malibu 1997-98 Oldsmobile Achieva, Cutlass 1997-98 Pontiac Grand Am, Sunfire with 2.2L, 2.4L, 3.1L Engine (VINs 4, T, M - RPOs LN2, LD9, L82) Condition Some owners may report the battery is weak or discharged; the starting motor may turn slowly; the generator is not charging and/or the generator Malfunction Indicator Lamp (MIL) may be on, possibly intermittent. Driveability symptoms may also be experienced. Cause If following steps 1, 2 or 3 of strategy based diagnostics did not reveal the cause, the generator output and battery positive cable terminal at the starting motor (CKT 1 - VIN T and M; CKT 2 - VIN 4) may be loose, causing a high resistance in the battery positive circuit from the generator to the battery. Correction Inspect the condition of the starting motor B+ stud, wire, ring terminals and nut. Clean each mating surface and replace damaged parts. Tighten positive battery B+ cable to starter solenoid nut to 12 N.m (106 lb in.). Refer to the "Starting Motor Replacement" portion in the Engine Electrical Section of the Service Manual. Recharge and load test the battery if required. Refer to "Battery Charging" in the Engine Electrical Section of the Service Manual. Important: The generator and battery are not damaged and should not require replacement. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time N6480 Wiring and/or Use published Connector, labor operation Starter - Repair time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 8070 Starter Motor: Specifications Type ..................................................................................................................................................... ........................................................................ SD255 No Load Test @ 10 volts Amps ...................... ............................................................................................................................................................. 50 - 75 RPM at Drive Pinion ................................................................................................................ ........................................................................ 6,000 - 12,000 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 8071 Starter Motor: Locations Lower Front Of Engine Lower Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 Starter Motor: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8096 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8097 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8098 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8099 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8100 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8101 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8102 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8103 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8104 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 8105 Starter Motor: Application and ID Type ..................................................................................................................................................... ........................................................................ SD255 No Load Test @ 10 volts Amps ...................... ............................................................................................................................................................. 50 - 75 RPM at Drive Pinion ................................................................................................................ ........................................................................ 6,000 - 12,000 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 8106 Starter Motor: Description and Operation Starter Motor (Typical) Standard starter motors consist of the drive mechanism, frame, field windings, armature and brushes. The armature is supported on bushings or hearings, depending on applications, to permit it to rotate freely. All the current that passes through the field coils also travels through the armature. As current enters the motor, it passes through the field windings, creating a magnetic field around the armature, then into the brushes which ride on the commutator. Finally, the current passes through the armature windings, thus creating a second magnetic field within the armature. The two strong magnetic fields oppose each other in such a way that the armature is forced to rotate. During starter operation, the solenoid windings are energized when the ignition switch is turned to the "START" position. The resulting plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear and the solenoid main contacts to close, and cranking takes place. When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch should he opened immediately when the engine starts. The starter motor field coils are permanently mounted in the frame. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Motor Noise Starter Motor: Testing and Inspection Starter Motor Noise Starter Motor Noise Diagnosis To correct starter motor noise during cranking, use the following procedure: 1. Determine the problem. 2. If the complaint is similar to problem 1 or 2, correction can be achieved by proper "shimming" as follows (vehicles are produced without shims from the factory): A. Check flywheel ring gear for damage - bent flywheel, unusual wear, etc. B. Shim starter as required: - Start noise during cranking: remove 1 - 0.015 inch double shim or add a single 0.015 inch shim to the outer bolt. - High pitched whine after engine starts: add 0.015 inch double shims until noise disappears (not to exceed 0.045 inch). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service Starter Motor: Service and Repair On-Vehicle Service Lubrication Starter motors do not require lubrication except during overhaul. Starter Replacement Starter Mounting REMOVE OR DISCONNECT 1. Negative battery cable. 2. Air inlet duct to throttle body. 3. Top starter bolt. 4. Raise vehicle. 5. Lower starter bolt. 6. Position engine wiring harness aside. 7. Position starter for access to solenoid wiring. 8. Electrical wiring. 9. Starter. INSTALL OR CONNECT 1. Electrical wiring. 2. Position starter to engine. 3. Lower starter bolt. Tighten Bolt to 90 N.m (66 lb. ft.). 1. Reposition engine wiring harness. 2. Lower vehicle. 3. Top starter bolt. 4. Air inlet duct to throttle body. 5. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8111 Starter Motor: Service and Repair Unit Repair Special Sealers, and Lubricants Shaft, Starter Armature .............................................................................................................................................................. Lubricant, GM P/N 1960954 Bushings, Starter ................................................................................... .................................................................................... Lubricant, GM P/N 1960954 Flange, Starter Solenoid ............................................................................................................................................... ................... Sealer, GM P/N 1050026 General Description There are two models of starters used on this vehicle, SD205 and SD255. Refer to "Specifications" for specific applications. Solenoid Replacement Starter Motor: Disassembled View (SD205/255) If a starter motor condition of no crank and no sound exist, check solenoid before dismantling. The solenoid can be checked for electrical operation without removal. Refer to "Cleaning, Inspection and Testing". Use the following procedure to remove the solenoid from the starter: REMOVE OR DISCONNECT 1. Field lead. 2. Solenoid to drive housing attaching screws and remove solenoid by twisting. INSTALL OR CONNECT NOTE: Whenever servicing the starter solenoid, the inner solenoid terminal nut(s) (if equipped) must be tightened before wiring and retaining nut(s) are installed. Failure to do so will result in solenoid terminal and/or cap damage. Tightening specifications are the same for the inner and outer solenoid terminal nuts. 1. Twist solenoid into position and install attaching screws. 2. Field lead. No-Load Test Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8112 No Load Test Make connection as shown. Close the switch and compare the RPM, current, and voltage readings with values shown in ''Starter Specifications". Use the test results as follows: 1. Rated current draw and no-load speed indicates normal condition of the starter motor. 2. Low free speed and high current draw indicates: - Too much friction - tight, dirty, or worn bushings, bent armature shaft allowing armature to drag. - Shorted armature. This can be further checked on a growler after disassembly. - Grounded armature or fields. Check further after disassembly. 3. Failure to operate with high current draw indicates: - A direct ground in the terminal or fields. - "Frozen" bearings. 4. Failure to operate with low or no current draw indicates: - Open solenoid windings. Check solenoid resistance values (See "Cleaning, Inspection and Testing"). See: Cleaning, Inspection and Testing - Open field circuit. This can be checked after disassembly by inspecting internal connections and tracing circuit with a test lamp. - Open armature coils. Inspect the commutator for badly burned bars after disassembly. - Broken brush springs, worn brushes, high insulation between the commutator bars or other causes which would prevent good contact between the brushes and commutator. 5. Low no-load speed and low current draw indicates: - High internal resistance due to poor connections, defective leads, dirty commutator and causes listed under step Number 4 above. 6. High free speed and high current draw usually indicate shorted fields. If shorted fields are suspected, replace the field and frame assembly. Also check for shorted armature, using a growler. Starter Disassembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8113 Starter Motor: Disassembled View (SD205/255) Armature Shaft And Drive Assembly MODELS SD205 AND SD255 Remove or Disconnect 1. Field lead attaching screw from solenoid terminal. 2. mm bolts, identification tag, and commutator end frame from motor assembly. If thru bolt heads are different, note location relative to field lead for later reassembly. 3. Brake washer from armature shaft. 4. Frame and field assembly from drive end housing and armature. 5. Armature with drive assembly from drive end frame by tilting to disengage drive collar from lever. Refer to "Cleaning, Inspection and Testing" to check drive assembly before further disassembly. 6. Solenoid attaching screws and solenoid from drive end housing. 7. Lever shaft retaining ring and lever shaft from drive end housing. Plunger and lever with return spring from drive end housing. If shift lever shaft does not have a retaining ring, drill out shaft and drive shaft out of the housing with a drift punch. A new shaft with retainer, service package 10457146, must be used on reassembly. 8. Thrust collar from armature shaft, then snap pinion stop collar off of retainer ring. Collar will remain on shaft next to drive pinion. 9. Retainer ring from groove in armature shaft. Ring is not reused; bend ring enough to avoid scratching armature shaft surface as ring is removed. 10. Pinion stop collar and drive from shaft. Cleaning, Inspection and Testing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8114 Testing Field For Open Testing Field For Ground Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8115 Testing Solenoid Winding 1. Clean all starting motor parts, but DO NOT USE GREASE DISSOLVING SOLVENTS FOR CLEANING. Solvent would dissolve the grease packed in the clutch and would damage armature and field coil insulation. Wipe parts with a clean shop cloth. 2. Test drive assembly action. The pinion should turn freely in the overrunning direction. Check pinion teeth to see that they have not been chipped, cracked, or excessively worn. Replace assembly if necessary. Badly chipped pinion teeth may indicate chipped teeth on the ring gear, which should be replaced if necessary. 3. Check the drive assembly for slipping by leaving the assembly attached to the armature, wrap the armature with a shop towel and clamp the armature in a vise. Using a 12-point deep socket and torque wrench, put the socket on the pinion and turn counterclockwise. The drive should not slip up to 68 N.m (50 lb. ft.). of torque. If it does, replace the drive assembly. 4. The roll type drive assembly should be wiped clean. DO NOT clean in any degreasing tank, or with grease dissolving solvents; this will dissolve the lubricant in the drive mechanism. 5. Inspect armature commutator. If commutator is dirty, clean with 400 grit polishing cloth then wipe clean. If commutator is rough, the armature should be replaced. Do not undercut or turn commutators. Inspect the points where the armature conductors join the commutator bars to make sure they have a good connection. A burned commutator bar is usually evidence of a poor connection. 6. If test equipment is available: A. Check the armature for short circuits by placing on growler and holding back saw blade over armature core while armature is rotated. If saw blade vibrates, armature is shorted. Recheck after cleaning between the commutator bars. If saw blade still vibrates, replace the armature. B. Check frame and field assembly by using a test lamp, place one lead on the field lead terminal and the other lead on one insulated brush. If the lamp fails to light, the series coil is open and will require repair or replacement. This test should be made from each insulated brush to check brush and lead continuity. C. Using a test lamp place one lead on the grounded brush holder and the other lead on either insulated brush. If the lamp lights, a grounded series coil is indicated and must be repaired or replaced. D. Check the current draw of the solenoid winding as follows: - If solenoid is not removed from starter motor, the field lead must be removed from the terminal on the solenoid before making these tests. Complete tests in a minimum of time to prevent overheating of the solenoid. - To check hold-in winding, connect an ammeter in series with 12-volt battery and the "switch" terminal on the solenoid. Connect a voltmeter to the "switch" terminal and to ground. Connect carbon pile across battery. Adjust the voltage to 10 volts and note the ammeter reading. - Readings should be 10 to 20 amperes. To check both windings, connect the same as for the previous test. Ground the solenoid motor terminal. Adjust the voltage to 10 volts and note the ammeter reading. It should be 60 to 85 amperes. - NOTE: Current will decrease as windings heat up. - Current draw readings that are over specifications indicate shorted turns or a ground in the windings of the solenoid and the solenoid should be replaced. Current draw readings that are under specifications indicate excessive resistance. A zero reading indicates an open circuit. Check connections then replace solenoid if necessary. 7. Starter solenoid switch is serviced as an assembly. Starter Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8116 Starter Motor: Disassembled View (SD205/255) Armature Shaft And Drive Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8117 Testing Solenoid Winding MODELS SD205 AND SD255 Install or Connect 1. Drive assembly to armature shaft as follows: A. Lubricate area on armature shaft that will he under drive assembly lightly with GM lubricant 1960954 or equivalent. B. Drive assembly onto armature shaft with pinion away from armature. C. Pinion stop collar onto armature shaft. D. New pinion stop retainer ring into groove on shaft. Do not re-use old ring. Installing Pinion Stop Collar E. Thrust collar to end of shaft with flange toward retainer ring. Use pliers as shown to snap pinion stop collar over retainer ring. Inspect Bushing (SD205) or Bearing (SD255) in drive end housing. If damaged, replace drive end housing. If dry, lubricate with GM lubricant P/N 1960954 or equivalent. Avoid excessive grease. 2. Shift lever yoke to drive collar, then armature/drive/lever assembly into drive end housing. 3. Shift lever shaft through holes in drive end housing and shift lever, then secure with retainer. Place return spring onto plunger. 4. Solenoid over plunger by depressing spring, aligning to drive end housing. Install attaching screws. 5. Frame and field assembly as follows: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8118 Testing Field For Open Testing Field For Ground Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8119 Brush Holder Inspect Brushes. If damaged or excessively worn replace brushes. - Use soft cloth to clean contact face of brushes in frame and field assembly. A. Apply sealer GM P/N 1050026 or equivalent to solenoid flange where frame and field will contact it. B. Push brushes into brush holders and hold. C. Install frame and field assembly over armature, aligning properly to drive end housing. D. Release brushes onto commutator. Be sure all four brushes move freely in holders and are in contact with commutator. 6. Brake washer onto armature shaft. Inspect - Bushing (SD205) or Bearing (SD255) in commutator end frame. If damaged, replace commutator end frame. If dry, lubricate with G.M. Lubricant P/N 1960954 or equivalent. Avoid excessive grease. 7. Commutator end frame onto armature shaft, aligning with frame and field assembly. 8. Identification tag onto one thru bolt, then two thru bolts to motor. If thru bolts have different heads, place as noted during disassembly. Tighten Bolts to 8.5 N.m (75 lb. in.). Measure Pinion clearance as follows: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > On-Vehicle Service > Page 8120 Checking Pinion Clearance CAUTION: Keep fingers, tools, and other objects away from opening in drive end housing while making electrical connections. The strong shifting action of the solenoid could cause personal injury or damage as the drive pinion moves into cranking position. A. Secure starting motor in vise or equivalent fixture so that opening in drive end housing is accessible for measurement. B. Assure that field lead is disconnected and insulated from solenoid terminal. C. Connect positive lead from a 12-volt battery to the solenoid "S" terminal. Connect negative lead from battery to clean ground on motor housing. This energizes hold-in coil. D. Momentarily ground solenoid "M" terminal to motor housing. This energizes pull-in coil in solenoid and causes drive pinion to move into cranking position. Drive pinion will stay in this position when momentary ground is removed. E. Press on drive just enough to take up any free movement of the pinion on the shaft. Use feeler gages to check clearance between end of pinion and pinion stop collar. Clearance should be 0.25 to 4.06 mm (0.010 inch to 0.160 inch). F. Disconnect negative (ground) lead from motor housing (drive pinion will retract into drive end housing), then disconnect positive lead from "S" terminal. G. If clearance is outside specifications, recheck motor for proper assembly and for worn or damaged parts in shift mechanism and drive assembly. Replace worn parts. H. Field lead to solenoid terminal. Tighten Screw to 8.5 N.m (75 lb. in.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Solenoid Lower Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Solenoid > Page 8125 Lower Front Of Engine Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions Starter Solenoid: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 Starter Solenoid: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8144 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8145 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8146 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8147 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8148 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Page 8159 Starter Solenoid: Service and Repair Starter Motor: Disassembled View (SD205/255) If a starter motor condition of no crank and no sound exist, check solenoid before dismantling. The solenoid can be checked for electrical operation without removal. Refer to "Cleaning, Inspection and Testing". See: Starter Motor/Service and Repair/Unit Repair/Cleaning, Inspection and Testing Use the following procedure to remove the solenoid from the starter: REMOVE OR DISCONNECT 1. Field lead. 2. Solenoid to drive housing attaching screws and remove solenoid by twisting. INSTALL OR CONNECT NOTE: Whenever servicing the starter solenoid, the inner solenoid terminal nut(s) (if equipped) must be tightened before wiring and retaining nut(s) are installed. Failure to do so will result in solenoid terminal and/or cap damage. Tightening specifications are the same for the inner and outer solenoid terminal nuts. 1. Twist solenoid into position and install attaching screws. 2. Field lead. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8183 Fuse: Locations Engine Compartment Fuse Relay Center LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8184 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8185 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8186 Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8187 Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Fuse: Application and ID Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 8190 Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 8191 Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Specifications Fuse Block: Specifications Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Page 8195 Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center Fuse Block: Locations Convenience Center RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8198 Fuse Block: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8199 Fuse Block: Locations Engine Compartment Fuse Relay Center LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8200 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8201 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8202 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8203 Fuse Block: Locations RH Upper I/P Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8204 Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8205 LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8206 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8207 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8208 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8209 LH Side Of Engine Compartment LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Harness Connector Convenience Center: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Harness Connector > Page 8212 Convenience Center: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 8215 Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations Lower Front Of Engine LH center of engine compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8223 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8224 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8225 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8226 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8227 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8228 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 8233 Relay Box: Application and ID Front View Of Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 8237 Relay Box: Application and ID Front View Of Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8246 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8247 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8248 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8254 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8255 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8256 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8261 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8262 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8263 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8264 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8265 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8266 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8271 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8277 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8278 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8279 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8280 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8281 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8282 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8287 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Power Outlet: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Auxiliary Power Outlet: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block Fuse: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8311 Fuse: Locations Engine Compartment Fuse Relay Center LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8312 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8313 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8314 Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block > Page 8315 Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Fuse: Application and ID Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 8318 Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 8319 Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Specifications Fuse Block: Specifications Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Specifications > Page 8323 Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center Fuse Block: Locations Convenience Center RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8326 Fuse Block: Locations Fuse Block Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8327 Fuse Block: Locations Engine Compartment Fuse Relay Center LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8328 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8329 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8330 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8331 Fuse Block: Locations RH Upper I/P Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8332 Component Location Views At the left end of the tie bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8333 LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8334 Positive Battery Cable To Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8335 Engine Wiring Harness To Fuse Block Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8336 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Convenience Center > Page 8337 LH Side Of Engine Compartment LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Harness Connector Convenience Center: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Harness Connector > Page 8340 Convenience Center: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block Front View Of Fuse Block Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Instrument Panel (I/P) Fuse Block > Page 8343 Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations Lower Front Of Engine LH center of engine compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8351 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8352 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8353 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8354 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8355 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 8356 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 8361 Relay Box: Application and ID Front View Of Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations LH Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 8365 Relay Box: Application and ID Front View Of Engine Compartment Fuse/Relay Center Front View Of Engine Compartment Fuse/Relay Center Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8374 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8375 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8376 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8382 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8383 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8384 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8389 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8390 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8391 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8392 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8393 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8394 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8399 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8405 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8406 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8407 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8408 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8409 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 8410 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 8415 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8421 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8422 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8423 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8424 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8425 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8426 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 8427 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 8430 Alignment: Specifications Alignment Specifications Front Caster ......................................................................................................................................... ............................. +3.30 to +5.30° (+4.30 +/- 1.00°) Front Camber ................................................... ................................................................................................................... -1.20 to +0.80° (-0.20 +/1.00°) Individual Toe ........................................................................................................................... ......................................... -0.07 to +0.17° (+0.05 +/- 0.12°) (Measure Toe Angles With Steering Wheel At Level Position, Visually Aligned With Column.) Sum Toe .............................................................................................................................................. ............................... -0.15 to +0.35° (+0.10 +/- 0.25°) Cross Camber ................................................. ...................................................................................................................... -1.00 to +1.00° (0.00 +/1.00°) (Slight Cross Camber Specification Differences Can Be Made When Servicing Vehicle For Steering Pull.) Cross Caster ........................................................................................................................................ ................................. -1.00 to +1.00° (0.00 +/- 1.00°) Rear Camber ................................................... .................................................................................................................... -1.00 to +0.50° (-0.25 +/0.75°) Rear Sum Toe .......................................................................................................................... .......................................... -0.10 to +0.50° (+0.20 +/- 0.30°) Rear Thrust Angle ................................ ................................................................................................................................ -0.25 to +0.25° (0.00 +/- 0.25°) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicle Ride (Trim) Height Specifications > Page 8431 Alignment: Specifications Torque Specifications Strut to Knuckle Nuts ........................................................................................................................... ................................................ 180 Nm (133 ft. lbs.) Tie Rod Jam Nut ............................................... ........................................................................................................................................ 75 Nm (55 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8432 Alignment: Service Precautions NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener tightening specification and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Definition of Terms Alignment: Description and Operation Definition of Terms Camber Camber is the tilting of the front wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is "positive" (+). When the wheels tilt inward at the top, the camber is "negative" (-). The amount of tilt is measured in degrees from the vertical. Camber setting will influence directional control and tire wear. Caster Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Definition of Terms > Page 8435 Caster is the tilting of the front steering axis (at the top) either forward or backward from the vertical. A backward tilt is "positive" (+) and a forward tilt is "negative" (-). Caster influences directional control of the steering but does not affect tire wear. Caster is affected by vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect the caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more "positive" caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less "positive" caster. Toe-In Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Definition of Terms > Page 8436 Toe is a measurement of how much the front of the wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is "positive" (+). When the wheels are turned out, toe is "negative" (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also serves to offset the small deflections of the wheel support system which occurs when the vehicle is rolling forward. In other words, even when the wheels are set to toe in or out slightly when the vehicle is standing still, they tend to roll parallel on the road when the vehicle is moving. Toe affects tire wear. Thrust Angle The front wheels aim or steer the vehicle, but the rear wheels control tracking. This tracking action is relative to thrust angle. Thrust angle is defined as the path that the rear wheels will take. Ideally, the thrust angle is geometrically aligned with the body centerline. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Definition of Terms > Page 8437 Alignment: Description and Operation General Description Wheel alignment refers to the angular relationship between the wheels, control arms, suspension and the ground. When measured, the vehicle should have a full fuel tank, no passengers, and with no other loading or items in the trunk or passengers compartment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 8438 Alignment: Testing and Inspection Some degree of torque steer to the right may normally be experienced during heavy throttle application on some front-wheel-drive vehicles that do not have equal length drive axles. This is due to the right drive axle being longer than the left axle and associated difference in axle angle. Vehicles with intermediate shaft assemblies have almost equal length axles. A difference in axle length results in more torque toe-in effect to the left front wheel. This condition can be noticed when accelerating from a standing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 8439 start or at lower speeds. A simple measurement to determine the degree of torque steer is to place a small piece of tape at the top center of the steering wheel. Drive the vehicle and note the inches of steering wheel deflection required to steer the vehicle straight under heavy acceleration. A comparison of like vehicles will then determine if a particular vehicle has a greater than normal degree of torque steer. The following factors may cause torque steer to be more apparent on a particular vehicle: ^ Large difference in right and left front tire pressure. ^ A slightly smaller diameter tire on the right front will increase a right torque lead. Inspect front tires for difference in brand, construction, or size. If the tires appear similar, change the front tires side to side and re-test the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. ^ Any looseness in control arm bushings, tie rod assemblies or steering gear mounting which permits a front wheel to pull forward and toe-in under torque more than the opposite side. A loose suspension component may also result in an opposite lead on deceleration. ^ High front trim height which would increase drive axle angle. ^ Binding or tight drive axle joint. A tight joint or high front trim height may also exhibit a wobble condition between 24 and 48 km/h (15 and 30 mph). ^ Incorrect, worn, or loose engine mounts causing adverse drive axle angles. ^ Unequal Engine/Transmission height from the left side to the right side of vehicle. If difference from side to side is more than 6 mm (17/64 inch), change trim heights by installing a stronger spring in the side which is lower, or a weaker spring in the side which is shorter than the specified "Z" heights. Replace only, do not shim engine mounts as this may cause other symptoms. ^ On occasion, side-to-side trim height differences may be the result of a faulty stabilizer shaft. To check this disconnect the stabilizer links, re-measure trim heights. If the side-to-side difference is corrected, replace the stabilizer shaft. If there is no change in trim height do not change the stabilizer shaft. A trim height difference of more than 6 mm (17/64 inch), indicates a possible bent, stabilizer shaft, attaching links, or a bent suspension component that may need replacement. The following conditions affect vehicle handling and/or a constant right or left lead separate from torque steer causes. The existence of one or more of these conditions may compound a torque steer complaint. ^ Incorrect front-wheel alignment or a rear-wheel alignment condition which would cause the vehicle to not track straight. A difference in the front wheel to rear wheel measurement compared side to side may indicate a "dog track" condition or one front wheel ahead of the other due to a misalignment or other condition. A substantial caster difference is an indication of misalignment or other condition. Front-wheel caster should be equal or within specifications and camber may be biased slightly to offset a lead condition. ^ Suspension support misalignment. ^ Front suspension damage, such as a bent strut. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection Alignment: Service and Repair Preliminary Inspection Steering and ride complaints are not always the result of improper alignment. Another possibility is tire "lead" due to worn or improperly manufactured tires. "Lead" is the vehicle's deviation from a straight path on a level road without pressure on the steering wheel. Refer to "Steering, Suspension, Tire And Wheels Diagnosis," for the procedure to determine if the vehicle has a lead problem. Before making any adjustment affecting wheel alignment, make the following inspections to ensure correct alignment readings and alignment adjustments. Inspect: 1. All tires for proper inflation pressures. Also check that tires have about the same tread wear. 2. Hub and bearing assemblies for excessive wear; correct if necessary. 3. Ball joints and tie rod ends; if they are loose, correct them before adjusting. 4. Run-out of wheels and tires. 5. Vehicle trim height. If out of limits and a correction is to be made, do so before adjusting alignment.. 6. Strut dampeners for proper operation. 7. Control arms for loose bushings. 8. Stabilizer shaft for loose or missing parts. 9. Suspension and steering components for damage and replace parts as necessary. Consideration must be given to excess loads, such as tool boxes, sample cases, etc. If these items are normally carried in the vehicle, they should remain in the vehicle during alignment adjustments. Loads such as these should be centered in the vehicle whenever possible to minimize their effects. Consideration should also be given to the condition of the equipment being used to adjust alignment. Be sure to follow the equipment manufacturer's instructions. Regardless of the equipment used to adjust alignment, the vehicle must be on a level surface, both fore-and-aft and sideways. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8442 Alignment: Service and Repair Ride/Trim Height Measurement and Adjustment Vehicle Ride Height Measurement Locations Prior to measuring vehicle trim height, prepare the vehicle as follows: 1. Check to be sure that: A. The fuel gage reads full. B. The spare tire and tools are properly located. C. The vehicle is free of ice, snow and mud accumulations. 2. Set front and rear tire pressure to within plus or minus 20 kPa (3 psi) of recommended pressure shown on tire placard. If two load conditions are shown on placard, use the lower load condition. 3. Close engine compartment hood and all doors. 4. Up to 7kg (15.5 lbs.) may be left in trunk if it is located approximately on vehicle centerline. Remove items necessary to meet this requirement. 5. Measure the vehicle trim height as follows: ^ "Z" and "J" Dimensions: Lift front bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. Push front bumper down approximately 38.0 mm (1 1/2 inch). Gently repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. True heights are the average of the high and low measurements. ^ "K" Dimension: Lift rear bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "K" dimension. Push rear bumper down approximately 38.0 mm (1 1/2 inch). Gently remove hand and let vehicle rise on its own. Repeat twice for a total of 3 times. Measure "K" dimension. True heights are the average of the high and low measurements. Trim Height Measurements Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8443 Prior to measuring vehicle trim height, prepare the vehicle as follows: 1. Check to be sure that: A. The fuel gage reads full. B. The spare tire and tools are properly located. C. The vehicle is free of ice, snow and mud accumulations. 2. Set front and rear tire pressure to within plus or minus 20 kPa (3 psi) of recommended pressure shown on tire placard. If two load conditions are shown on placard, use the lower load condition. 3. Close engine compartment hood and all doors. 4. Up to 7kg (15.5 lbs.) may be left in trunk if it is located approximately on vehicle centerline. Remove items necessary to meet this requirement. 5. Measure the vehicle trim height as follows: ^ "Z" and "J" Dimensions: Lift front bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. Push front bumper down approximately 38.0 mm (1 1/2 inch). Gently repeat twice for a total of 3 times. Measure "Z" and "J" dimensions. True heights are the average of the high and low measurements. ^ "K" Dimension: Lift rear bumper of vehicle up approximately 38.0 mm (1 1/2 inch). Gently remove hands and let vehicle settle. Repeat twice for a total of 3 times. Measure "K" dimension. Push rear bumper down approximately 38.0 mm (1 1/2 inch). Gently remove hand and let vehicle rise on its own. Repeat twice for a total of 3 times. Measure "K" dimension. True heights are the average of the high and low measurements. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8444 Alignment: Service and Repair Front Wheel Alignment Measuring Front Alignment Angles Important: ^ Install alignment equipment following equipment manufacturer's instructions. ^ Jounce front and rear bumpers three times to normalize suspension prior to measuring angles. ^ Measure alignment angles and record the readings. If adjustments are necessary, make them in the following order: 1. Camber. 2. Toe. Front Caster Adjustment Caster is not adjustable. If the caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace parts as necessary. Refer to "Body And Frame" to determine proper underbody alignment. Front Camber Adjustment Important: When camber adjustment is necessary, Refer to "Front Suspension" for instructions on modifying the front strut. GENERAL PROCEDURE ^ Loosen both strut to knuckle nuts just enough to allow movement. ^ Adjust the camber to specification by moving top of wheel in or out. Refer to "Specifications." ^ Tighten the strut-to-knuckle nuts to 180 Nm (133 ft. lbs.). Front Toe Adjustment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8445 DISASSEMBLE 1. Be sure steering wheel is set in a straight ahead position within +/- 5 degrees. 2. Loosen jam nut. 3. Adjust toe to specification by turning adjuster. 4. Tighten jam nut to 75 Nm (55 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Preliminary Inspection > Page 8446 Alignment: Service and Repair Rear Wheel Alignment Rear wheel alignment is not adjustable. If the camber and toe angles are not within the specifications, inspect for underbody or rear suspension damage. Refer to "Body And Frame" to determine proper underbody alignment. After front wheel alignment has been completed the rear alignment angles should be checked if there is excessive rear tire wear or wheels do not track properly. Rear wheels should be parallel to and the same distance from the vehicles centerline. If tires do not track correctly after a front wheel alignment, no amount of adjustment will correct the problem. Poor tracking or excessive rear tire wear after a front wheel alignment usually indicates that the axle housing, frame, or suspension arms have been bent. Refer to "Specifications" for rear alignment angles. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Various Revised Tightening Specifications Front Steering Knuckle: Technical Service Bulletins Steering - Various Revised Tightening Specifications CHEVROLET 73-32-03A Issued: 05/01/97 SMU - SECTIONS 3B/3C/4D REVISION: 04/11/97 THIS BULLETIN IS BEING REVISED TO UPDATE THE DRIVE AXLE NUT TIGHTENING SPECIFICATIONS FOR THE N CAR. PLEASE DISCARD CORPORATE BULLETIN NUMBER 73-32-03 (SECTION 3 - STEERING/SUSPENSION). SUBJECT: SERVICE MANUAL UPDATE - SECTIONS 3B/3C/4D - REVISED TIGHTENING SPECIFICATIONS MODELS: 1997 CHEVROLET CAVALIER, MALIBU 1997 OLDSMOBILE CUTLASS 1997 PONTIAC SUNFIRE THIS BULLETIN IS BEING ISSUED TO REVISE THE TIGHTENING SPECIFICATIONS IN SECTIONS 3B, 3C AND 4D OF THE SERVICE MANUAL AS FOLLOWS: J CAR SECTIONS 3B-8, 3B-9, 3C-5 AND 3C-13: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 90 DEGREE ROTATION. N CAR SECTIONS 3C-6 AND 3C-16: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 180 DEGREE ROTATION. SECTION 3B-12: THE CORRECT TIGHTENING SPECIFICATIONS ARE AS FOLLOWS: - STEERING COLUMN LOWER PINCH BOLT 22 N.M (16 LB FT) - STEERING COLUMN UPPER PINCH BOLT 22 N.M (16 LB FT) SECTIONS 3C-16, 4D-4 AND 4D-5: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - FRONT DRIVE AXLE NUT 385 N.M (284 LB FT) +/- 5 N.M (44 LB IN). REPLACE THE DRIVE AXLE NUT WITH A NEW ONE AFTER EVERY REMOVAL. NEVER RE-USE THE DRIVE AXLE NUT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service Front Steering Knuckle: Service and Repair On-Vehicle Service Ball Joint and Knuckle Inspection Ball joints must be replaced if any looseness is detected in the joint or the ball joint seal is cut. To inspect the ball joints, raise the front of the vehicle allowing the front suspension to hang free. Grasp the tire at the top and bottom and move the top of tire with an in-and-out motion. Observe ball joint for any horizontal movement of the steering knuckle relative to the front lower control arm. If the ball stud is disconnected from the steering knuckle and any looseness is detected, or if the ball stud can be twisted in its socket using finger pressure, replace the ball joint. Ball stud tightness in the steering knuckle boss should also be checked when inspecting the ball joint. This may be done by shaking the wheel and feeling for movement of the stud end or castellated nut at the knuckle boss. Checking the castellated nut fastener tightening specification is an alternative method of inspecting for wear A loose nut can indicate a bent stud or an "opened-up" hole in the knuckle boss. Worn or damaged ball joints and knuckles must be replaced. Steering Knuckle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service > Page 8454 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service > Page 8455 ^ Tools Required: J 38892 Ball Joint Separator - J 28733-A Front Hub Spindle Remover - Or Equivalents REMOVE OR DISCONNECT 1. Hub and bearing assembly. 2. Bolts attaching steering knuckle to strut. INSTALL OR CONNECT 1. Steering knuckle into strut and install steering knuckle-to-strut assembly bolts. ^ Tighten steering knuckle-to-strut assembly nuts to 180 Nm (133 ft. lbs.). 2. Hub and bearing assembly onto knuckle and install hub and bearing assembly bolts. 3. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service > Page 8456 Front Steering Knuckle: Service and Repair Strut and Knuckle Scribing 1. Using a sharp tool, scribe the knuckle along the lower outboard strut radius as shown. 2. Scribe the strut flange on the inboard side along the curve of the knuckle, as shown. 3. Make a scribe mark across the strut/knuckle interface as shown. 4. On reassembly, carefully match the marks to the components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications GM Power Steering Fluid P/N 1050017 or Equivalent GM Cold Climate Power Steering Fluid P/N 12345866 or Equivalent Complete System Capacity ................................. ...................................................................................................................................................... 0.70 Liters - 1 1/2 Pints Pump Only ........................................................................................................................................... ..................................................... 0.50 Liters - 1 Pint Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement Power Steering Line/Hose: Service and Repair Gear Inlet Hose Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 8468 REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear inlet hose from pump. 4. Raise vehicle. 5. Gear inlet hose from steering gear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 8469 INSTALL OR CONNECT 1. Route new gear inlet hose to steering gear. 2. Gear inlet hose to steering gear. 3. Lower vehicle. 4. Install gear inlet hose to pump. ^ Tighten gear inlet hose assembly to 27 Nm (20 ft. lbs.). 5. Fill and bleed power steering system. ^ Bleed air from system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 8470 Power Steering Line/Hose: Service and Repair Gear Outlet Hose Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Gear Inlet Hose Replacement > Page 8471 REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear outlet hose from pump after sliding spring clamp back. 4. Line retainer (if applicable). 5. Gear inlet hose assembly from rack and pinion steering gear. 6. Gear outlet hose assembly from rack and pinion steering gear. 7. Gear outlet pipe and/or hose from vehicle. INSTALL OR CONNECT 1. Gear outlet hose assembly into position on vehicle. 2. Gear outlet hose assembly to rack and pinion steering gear. Tighten outlet hose assembly to 27 Nm (20 ft. lbs.). 3. Gear inlet hose assembly to rack and pinion steering gear. Tighten hose assembly to 27 Nm (20 ft. lbs.). 4. Line retainer (if applicable). 5. Gear outlet hose to pump and hose clamp. Important: Fill and Bleed air from system. 6. Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > On-Vehicle Service Power Steering Pump: Specifications On-Vehicle Service Power Steering Pump: Fitting ................................................................................................................................................... ................................................ 75 Nm (55 ft. lbs.) Hose Fitting Nut .................................................... ............................................................................................................................... 27 Nm (20 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > On-Vehicle Service > Page 8480 Power Steering Pump: Specifications Unit Repair End Plug .............................................................................................................................................. .................................................. 75.0 Nm (55 ft. lbs.) O-ring Union Fitting .......................................... .................................................................................................................................... 75.0 Nm (55 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service Precautions > Technician Safety Information Power Steering Pump: Technician Safety Information WARNING: This vehicle is equipped with a Supplemental Restraint System (SRS). Failure to follow WARNINGS could result in possible air bag deployment, personal injury, or otherwise unneeded SRS repairs. WARNING: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service Precautions > Technician Safety Information > Page 8483 Power Steering Pump: Vehicle Damage Warnings NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service Precautions > Page 8484 Power Steering Pump: Description and Operation A pressure-relief valve inside the flow control valve limits pump pressure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Diagnostic Information & Procedures Power Steering Pump: Testing and Inspection Diagnostic Information & Procedures GENERAL PROCEDURE Inspect for: ^ Overfilled reservoir. ^ Fluid aeration and overflow. ^ Hose connections. ^ Verify exact point of leakage. Example: The point from which the fluid is dripping is not necessarily the point where the system is leaking. Fluid overflowing from the reservoir may appear to be dripping from the bottom of the housing. Important: When service is required: A. Clean leakage area upon disassembly. B. Replace leaking seal. C. Check component sealing surfaces for damage. D. Reset bolt tightening specification, where required. Important: Some complaints about the power steering system may be reported as: A. Fluid leakage on garage floor. B. Fluid leaks visible on steering gear or pump. C. Growling noise, especially when parking or when engine is cold. D. Loss of power steering when parking. E. Heavy steering effort. ^ When troubleshooting these kinds of complaints, check for an external leak in the power steering system. EXTERNAL LEAKAGE CHECK Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Diagnostic Information & Procedures > Page 8487 The purpose of this procedure is to pinpoint the location of the leak. In some cases, the leak can easily be located. But, seepage-type leaks may be more difficult to isolate. To locate seepage leaks, use the following method. 1. With the engine off, wipe dry the complete power steering system. 2. Check the fluid level in the pump's reservoir. Adjust fluid level as necessary. 3. Start the engine, then turn the steering wheel from stop to stop several times. Do not hold it at a stop for any length of time, as this can damage the power steering pump. It is easier if someone else operates the steering wheel while you search for the seepage. 4. Find the exact area of the leak and repair leak. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Diagnostic Information & Procedures > Page 8488 Power Steering Pump: Testing and Inspection Diagnosis By Symptom Power Rack and Pinion Steering Gear HISSING NOISE There is some noise in all power steering systems. One of the most common is a hissing sound when the steering wheel is turned and the vehicle is not moving. This noise will be most evident when turning the wheel while the brakes are applied. There is no relationship between this noise and steering performance. Do not replace the valve and pinion unless the "hissing" noise is extremely objectionable. A replacement valve and pinion will also have a slight noise, and is not always a cure for the condition. Check that the intermediate shaft joints are not loose. RATTLE OR CHUCKING NOISE Inspect for: ^ Power steering hose or line grounding out. ^ Tie rod ends loose. ^ Loose steering gear mounting. ^ Rack bearing preload loose. ^ Intermediate shaft boot mispositioned. POOR RETURN OF STEERING WHEEL TO CENTER Inspect for: ^ Front-wheel alignment. ^ Hub and bearing assembly worn. ^ Intermediate shaft binding or loose. ^ Tie rod end binding. ^ Ball joint binding. ^ Tight or frozen steering shaft bearings. ^ Rack bearing preload. ^ Sticky or plugged valve and pinion. ^ Intermediate shaft boot mispositioned. MOMENTARY INCREASE IN EFFORT WHEN TURNING WHEEL FAST TO RIGHT OR LEFT (ESPECIALLY WHEN COLD) Inspect for: ^ High internal leakage in gear or pump. ^ Hose pinched or restricted. ^ Sticking flow control valve. ^ Low fluid level in pump reservoir. STEERING WHEEL SURGES OR JERKS WHEN TURNING WITH ENGINE RUNNING (ESPECIALLY DURING PARKING, OR COLD) Inspect for: ^ Belt slipping. ^ Insufficient pump pressure. EXCESSIVE WHEEL KICKBACK OR LOOSE STEERING Inspect for: ^ Air in system. ^ Steering gear attachments loose. ^ Intermediate shaft loose. ^ Tie rod ends loose. ^ Hub and bearing assembly worn. ^ Rack bearing preload. HARD STEERING OR LACK OF ASSIST (ESPECIALLY DURING PARKING) Inspect for: ^ Loose or worn intermediate shaft. ^ Loose belt. ^ Insufficient pump pressure. ^ High internal leakage in gear or pump. Power Steering Pump FOAMING, MILKY POWER STEERING FLUID, LOW FLUID LEVEL, AND POSSIBLE LOW PRESSURE This can be caused by air in the fluid, and loss of fluid due to internal pump leakage causing overflow. Check for leak and correct. Bleed the system. Extremely cold temperatures will cause air bubbles in the system if the fluid level is low. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Diagnostic Information & Procedures > Page 8489 LOW PRESSURE DUE TO STEERING PUMP Inspect for: ^ Stuck or inoperative flow control valve. ^ Pressure plate not flat against cam ring. ^ Extreme wear of cam ring. ^ Scored pressure plate, thrust plate or rotor. ^ Vanes sticking in rotor slots. ^ Cracked or broken thrust or pressure plate. ^ High internal leakage. LOW PRESSURE DUE TO STEERING GEAR Inspect for: ^ Scored housing bore. ^ Leakage at seals. ^ Leakage at piston ring. ^ Air in system. GROWLING NOISE IN STEERING PUMP Inspect for: ^ Excessive back pressure in hoses or steering gear caused by restriction. ^ Scored pressure plates, thrust plate or rotor. ^ Hose or line grounding out. ^ Worn cam ring. ^ Low fluid level. ^ Air in system. GROANING NOISE IN STEERING PUMP Inspect for: ^ Air in the fluid. ^ Hose or line grounding out. ^ Low fluid level. ^ Pump mounting loose. RATTLING NOISE IN STEERING PUMP Inspect for: ^ Vanes sticking in rotor slots. SWISHING NOISE IN STEERING PUMP Inspect for: ^ Damaged flow control valve. WHINING NOISE IN STEERING PUMP Inspect for: ^ Scored pressure plates and vanes. ^ Low fluid level. Power Steering Pump Diagnosis FOAMING, MILKY POWER STEERING FLUID, LOW FLUID LEVEL, AND POSSIBLE LOW PRESSURE This can be caused by air in the fluid, and loss of fluid due to internal pump leakage causing overflow. Check for leak and correct. Bleed the system. Extremely cold temperatures will cause air bubbles in the system if the fluid level is low. LOW PRESSURE DUE TO STEERING PUMP Inspect for: ^ Stuck or inoperative flow control valve. ^ Pressure plate not flat against cam ring. ^ Extreme wear of cam ring. ^ Scored pressure plate, thrust plate or rotor. ^ Vanes sticking in rotor slots. ^ Cracked or broken thrust or pressure plate. ^ High internal leakage. LOW PRESSURE DUE TO STEERING GEAR Inspect for: ^ Scored housing bore. ^ Leakage at seals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Diagnostic Information & Procedures > Page 8490 ^ Leakage at piston ring. ^ Air in system. GROWLING NOISE IN STEERING PUMP Inspect for: ^ Excessive back pressure in hoses or steering gear caused by restriction. ^ Scored pressure plates, thrust plate or rotor. ^ Hose or line grounding out. ^ Worn cam ring. ^ Low fluid level. ^ Air in system. GROANING NOISE IN STEERING PUMP Inspect for: ^ Air in the fluid. ^ Hose or line grounding out. ^ Low fluid level. ^ Pump mounting loose. RATTLING NOISE IN STEERING PUMP Inspect for: ^ Vanes sticking in rotor slots. SWISHING NOISE IN STEERING PUMP Inspect for: ^ Damaged flow control valve. WHINING NOISE IN STEERING PUMP Inspect for: ^ Scored pressure plates and vanes. ^ Low fluid level. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service Power Steering Pump: Service and Repair On-Vehicle Service REMOVE OR DISCONNECT 1. Lines at pump. 2. Bolts (2). 3. Pump. INSTALL OR CONNECT 1. Pump. 2. Bolts (2). ^ Tighten pump mounting bolts to 26 Nm (19 ft. lbs.). 3. Lines at pump. ^ Tighten power steering gear inlet pipe to pump to 27 Nm (20 ft. lbs.). 4. Fill with fluid and bleed air from power steering system. ^ Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8493 Power Steering Pump: Service and Repair Unit Repair Reservoir Assembly REMOVE OR DISCONNECT 1. Pump assembly from vehicle, if necessary for access. 2. Retaining clips (3) and (5) from reservoir assembly (2) and housing (10). 3. Reservoir (2) from housing (10). 4. O-ring seal (8) from reservoir (2). INSTALL OR CONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8494 1. Lubricate new O-ring (8) with power steering fluid. ^ O-ring seal (8) to reservoir (2). 2. Reservoir assembly (2) to housing (10). 3. Retaining clips (3) and (5) to reservoir (2) and housing (10). 4. Pump assembly to vehicle, if removed. Control Valve REMOVE OR DISCONNECT 1. Pump assembly from vehicle, if necessary for access. 2. O-ring union fitting (16) and O-ring (15) or Variable Assist Steering actuator, if so equipped. ^ If pump is equipped with a Variable Assist Steering actuator, remove actuator (22) and discharge fitting (17). 3. Control valve assembly (13). 4. Flow control spring (12). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8495 INSTALL OR CONNECT 1. Flow control spring (12). 2. Control valve assembly (13). 3. Lubricate new O-ring (15) with power steering fluid. ^ O-ring (15) on fitting (16). 4. Fitting (16) and O-ring seal (15) or Variable Assist Steering actuator (22), if so equipped. ^ If pump is equipped with a Variable Assist Steering actuator, install actuator (22) and discharge fitting (17). ^ Tighten fitting (16) to 75 Nm (55 ft. lbs.). 5. Pump assembly to vehicle, if removed. Drive Shaft Seal (Without Disassembly of Pump) ^ Tool Required: J 7728 Shaft Oil Seal Installer - Or Equivalent REMOVE OR DISCONNECT 1. Pump assembly from vehicle, if necessary for access. 2. Protect drive shaft (7) with shim stock. 3. Seal (11) and discard. (Use small chisel to cut drive shaft seal.) INSTALL OR CONNECT 1. New drive shaft seal (11), lubricated with power steering fluid, using tool J 7728. 2. Pump assembly to vehicle, if removed. Hydraulic Pump Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8496 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8497 ^ Tool Required: J 7728 Shaft Oil Seal Installer - Or Equivalent DISASSEMBLE 1. Retaining ring (37) using punch in access hole. 2. Internal components of pump from pump housing (10) by gently pushing on drive shaft (7). ^ Components should include pressure plate sub-assembly consisting of: End cover (36). - O-ring seal (35). - Pressure plate spring (33). - Pressure plate (31). ^ Drive shaft sub-assembly consisting of: Pump rotor (28). - Thrust plate (25). - Drive shaft (7). - Shaft retaining ring (30). - Pump ring (26) and vanes (27). 3. O-ring (32) from pump housing (10). 4. Dowel pins (6). 5. Drive shaft seal (11). 6. End cover (36), pressure plate spring (33) and O-ring (35) from pressure plate (31). 7. Pump ring (26) and vanes (27) from drive shaft subassembly. 8. Shaft retaining ring (30) from drive shaft (7). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8498 9. Pump rotor (28) and thrust plate (25) from drive shaft (7). ^ Clean: All parts in power steering fluid. - Dry parts. ^ Inspect: Pressure plate (31). - Pump ring (26). - Rotor (28). - Vanes (27). - Thrust plate (25). - Drive shaft (7). - If scoring, pitting or chatter marks are noted, replace appropriate parts. ASSEMBLE 1. Lubricate new drive shaft seal (11) with power steering fluid. ^ Drive shaft seal (11) into pump housing (10) with tool J 7728. 2. Pump ring dowel pins (6) into pump housing (10). 3. Thrust plate (25) and pump rotor (28) to drive shaft (7). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8499 4. New shaft retaining ring (30) onto drive shaft (7). 5. Drive shaft sub-assembly into pump housing (10). 6. Vanes (27) into pump rotor (28). 7. Pump ring (26), with holes positioned correctly onto dowel pins (6), in pump housing (10) (see Figure 6). 8. Lubricate new O-ring (32) with power steering fluid. ^ O-ring (32) into groove in pump housing (10). 9. Pressure plate (31). 10. Pressure plate spring (33). 11. Lubricate new O-ring (35) with power steering fluid. ^ O-ring (35) into end cover (36). 12. Lubricate outer edge of end cover (36) with power steering fluid. 13. Press end cover (36) into pump housing (10). 14. Retaining ring (37) into groove in pump housing (10), with ring opening near access hole in pump housing. Control Valve Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8500 REMOVE OR DISCONNECT 1. Pump assembly from vehicle, if necessary for access. 2. Housing plug (39) and 0-ring (15). 3. Flow control spring (12). 4. Control valve (13). INSTALL OR CONNECT 1. Control valve (13). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8501 2. Flow control spring (12). 3. O-ring (15) and housing plug (39). ^ Tighten housing plug (39) to 75 Nm (55 lbs. ft.). 4. Pump assembly to vehicle, if removed. Face Seal NOTICE: This procedure is completed without the disassembly of the pump. REMOVE OR DISCONNECT 1. Pump assembly from vehicle. 2. Face seal (11) from pump. Lift seal from face of pump housing. Separate from shaft seal and pilot assembly in housing (10). Do not damage housing surface under flat face of seal. INSTALL OR CONNECT 1. Face seal to pump. Locate seal on shaft seal and pilot assembly in housing. Seal is installed properly with either side out. 2. Pump assembly into vehicle. Hydraulic Pump Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8502 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8503 DISASSEMBLE 1. Retaining ring (30) using punch in access hole. 2. Internal components of pump from pump housing by gently pushing on drive shaft (7). ^ Components should include pressure plate sub-assembly consisting of: End cover (36). - O-ring seal (35). - Pressure plate spring (33). - Pressure plate (31). ^ Drive shaft sub-assembly consisting of: Pump rotor (28). - Thrust plate (25). - Drive shaft (7). - Shaft retaining ring (30). - Pump ring (26) and vanes (27). 3. O-ring from pump housing. 4. Dowel pins (6). 5. End cover (36), pressure plate spring (33), pressure plate (31) and O-ring (35) from end cover (35). 6. Pump ring (26) and vanes (27) from drive shaft subassembly. 7. Shaft retaining ring (30) from drive shaft (7). 8. Pump rotor (28) and thrust plate (25) from drive shaft (7). ^ Clean: All parts in power steering fluid. - Dry all parts. ^ Inspect: Pressure plate (31). - Pump ring (26). - Rotor (28). - Vanes (27). - Thrust plate (25). - Drive shaft (7). - Face seal (11). - If scoring, pitting or chatter marks are noted, replace appropriate parts. ASSEMBLE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8504 1. Pump ring dowel pins (6) into pump housing (10). 2. Thrust plate (25) and pump rotor (28) to drive shaft (7). 3. New shaft retaining ring (30) onto drive shaft (7). 4. Drive shaft sub-assembly into pump housing (10). 5. Pump ring (26) with holes positioned correctly onto dowel pins (6), in pump housing (10). 6. Vanes (27) into pump rotor. 7. Lubricate new O-ring (32) with power steering fluid. ^ O-ring (32) into groove in pump housing (10). 8. Pressure plate (31). 9. Pressure plate spring (33). 10. Lubricate new O-ring with power steering fluid. ^ O-ring (35) into end cover (36). 11. Lubricate outer edge of end cover (36) with power steering fluid. ^ Press end cover (36) into pump housing (10). 12. Retaining ring (37) into groove in pump housing (10), with ring opening near access hole in pump housing (10). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8505 Important: Retaining ring opening must be located next to mounting boss. Seal Replacement Lip seals, which seal rotating shafts, require special treatment. This type of seal is used on the steering gear at the pinion shaft and on the drive shaft of the pump. When a leak occurs in this area, always replace the seal after inspecting and thoroughly cleaning the sealing surface. Replace the shaft only if very severe pitting is found. If the corrosion in the lip seal contact zone is slight, clean the surface of the shaft with crocus cloth. Replace the shaft only if the leakage cannot be stopped by smoothing with crocus cloth first. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8506 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement ^ Tools Required: J 25034-B with J 37609 J 25033-B Installer; or - J 36015 Power Steering Pulley Installer - Or Equivalents REMOVE OR DISCONNECT 1. Belt from pulley. 2. Pump from engine for tool clearance. ^ It is not necessary to remove the pressure and return lines from the pump. 3. Pulley using J 250318 with 37609. INSTALL OR CONNECT 1. Pulley using J 25033-B. Important: ^ Face of pulley hub must be flush with pump drive shaft. ^ Do not use arbor press to install pulley. 2. Pump to engine. 3. Belt on pulley. ^ Adjust belt tension. 4. Bleed power steering system if pump was removed from engine. ^ Inspect for leaks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > On-Vehicle Service > Page 8507 Power Steering Pump: Service and Repair Seal Replacement Recommendations Lip seals, which seal rotating shafts, require special treatment. This type of seal is used on the steering gear at the valve and pinion and on the drive shaft of the pump. When there is a leak in one of these areas, always replace the seal(s), after inspecting and thoroughly cleaning the sealing surfaces. Replace the shaft only if very severe pitting is found. If the corrosion in the lip seal contact zone is slight, clean the surface of the shaft with crocus cloth. Replace the shaft only if the leakage cannot be stopped by first smoothing with crocus cloth. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel to the straight ahead position. ^ Remove the key from the ignition switch. 1. The AIR BAG fuse from the I/P fuse block. 2. The I/P sound insulator - (LH). 3. The Connector Position Assurance (CPA) and the driver yellow 2-way connector located at the base of the steering column. 4. The Connector Position Assurance (CPA) and the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8513 IMPORTANT With the AIR BAG fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is normal operation and does not indicate a SIR system malfunction. Enabling the SIR System INSTALL OR CONNECT ^ Remove the key from the ignition switch. 1. The passenger yellow 2-way connector and the CPA located near the base of the steering column. 2. The driver yellow 2-way connector and the CPA located at the base of the steering column. 3. The I/P sound insulator - (LH). 4. The AIR BAG fuse to the I/P fuse block. Staying well away from both air bags, turn the ignition switch to the RUN position. Verify that the AIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8514 BAG warning lamp flashes seven times and then stays off. If the AIR BAG warning lamp does not operate as described, perform the SIR DIAGNOSTIC SYSTEM CHECK. See: Restraint Systems/Air Bag Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8515 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn off the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR System prevents deploying of the air bags from the reserve energy supply power. Refer to Disabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation Technical Service Bulletin # 02049 Date: 030101 Recall - Steering Gear Lower Pinion Bearing Separation File In Section: Product Recalls Bulletin No.: 02049 Date: January, 2003 PRODUCT SAFETY RECALL SUBJECT: 02049 - POWER STEERING GEAR LOWER PINION BEARING SEPARATION MODELS: 1996-1998 CHEVROLET CAVALIER 1996 CHEVROLET LUMINA APV 1997-1998 CHEVROLET VENTURE 1996-1998 PONTIAC SUNFIRE, TRANS SPORT 1997-1998 PONTIAC GRAND PRIX 1996-1998 OLDSMOBILE SILHOUETTE CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Pontiac Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles. Some of these vehicles have a condition where the lower pinion bearing in the power steering gear may separate. Most reports indicate the driver experienced an intermittent loss of power steering assist when making left turns, usually at low speeds. Power assist is normal in right hand turns. When trying to turn left, some drivers could experience higher resistance or, in a few cases, assist towards the right. If this happens while the vehicle is moving, a crash could result. CORRECTION Dealers are to inspect the condition of the lower pinion bearing and replace the lower pinion bearing, or in a few cases, replace the rack and pinion steering gear assembly. VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8524 Involved are certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of parts required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of January 13, 2003. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8525 CSO = Customer Special Order. SPECIAL TOOL Beginning the week of December 23, 2002, each dealer will be shipped a Power Steering Pinion Bearing Replacer, J44714-A, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-GM-TOOLS (1-800-468-6657). RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CUSTOMER REIMBURSEMENT Customer requests for reimbursement of previously paid repairs to replace the power steering gear lower pinion bearing or steering gear due to lower pinion bearing separation are to be submitted by January 31, 2004 (this time limit may be longer depending on the law in your state/province/country). All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following. - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s), a description of the repair, and the person or entity performing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8526 the repair. Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8527 Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Information Important If a vehicle has had the power steering gear lower pinion bearing or steering gear replaced prior to this recall, the applicable service procedures shown will still need to be performed on the vehicle. 1996 Lumina APV, Trans Sport, and Silhouette Lower Pinion Bearing Inspection (Includes Steering Gear Replacement, If Required) Because of limited access in this vehicle, the pinion bearing can only be inspected after the steering gear has been removed from the vehicle. For additional information on steering gear removal and bleeding the system, see the steering section of the appropriate service manual. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Remove both wheel and tire assemblies. 6. Remove the cotter pins and nuts from both outer tie rod ends. 7. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8528 8. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 11. Disconnect the pressure and return lines from the steering gear. 12. Remove the two bolts that attach the steering gear to the engine cradle 13. Separate the intermediate steering shaft cover (boot) from the steering gear. 14. Remove the steering gear from the vehicle. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 15. On a suitable work surface, remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to step 31 and replace the complete steering gear assembly. 16. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 17. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8529 18. Remove the lower retaining snap ring (1), see Figure 3. 19. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 20. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8530 21. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 22. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. 23. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 24. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 25. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. Lightly tap with a hammer until the bearing is seated in the housing. 26. Install a new snap ring. When properly installed, the large lug (1) on the snap ring must be on the right side as shown in Figure 9. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8531 27. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft) 28. Install a new dust cap (2) to the steering gear housing. 29. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 30. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 31. If installing a new steering gear, transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 32. If installing a new steering gear, remove the tie rod ends from the old steering gear. 33. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 34. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 30 Nm (22 lb ft) plus 120 degrees (or 2 flats of the nut). 35. Install the steering gear to the engine cradle in the vehicle. 36. Install the two bolts attaching the steering gear to the cradle. Tighten to 80 Nm (59 lb ft). 37. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 38. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 39. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 165 Nm (122 lb ft). 40. Reposition the intermediate steering shaft cover (boot) and attach to the steering gear. 41. Connect the outer tie rod ends to the steering knuckles and install the nuts. Tighten the nuts to 10 Nm (88 lb in) and then tighten the nuts an additional 180 degrees (1/2 turn). If necessary, rotate (tighten) the nuts to align the hole and install the cotter pins. 42. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 43. Lower the vehicle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8532 44. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 45. Install the driver's side insulator panel under the IP. 46. Add power steering fluid as necessary and bleed the system 47. Check alignment and set toe-in as necessary. 48. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 6. Lower the rear of the engine cradle as necessary to access steering gear. 7. Remove the left and right side stabilizer bar links from the lower control arms. 8. Reposition the stabilizer bar to improve access to the steering gear. 9. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 10. Remove the two bolts that attach the steering gear to the engine cradle. 11. Remove the steering gear from the cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 12. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 13. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 14. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 15. Remove the lower remaining snap ring (1), see Figure 3. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8533 16. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 17. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 18. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6 Finger tighten the forcing screw to push the puller legs against the bearing. 19. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 20. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 21. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 22. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 23. Install a new snap ring, Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 24. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 25. Install a new dust cap (2) to the steering gear housing. 26. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 27. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 28. Reinstall the steering gear in the engine cradle mounting brackets. 29. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 30. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 31. Reposition the stabilizer bar. 32. Install the left and right side stabilizer bar links to the lower control arms. Tighten the bolts to 23 Nm (17 lb ft). 33. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 34. Install the two rear engine cradle attaching bolts. Tighten to 165 Nm (122 lb ft). 35. Lower the vehicle 36. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 37. Install the driver's side insulator panel under the IP. 38. Check the power steering fluid and add if necessary. 39. Check alignment and set toe-in as necessary. 40. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8534 2. Loosen the outer tie rod adjuster nuts. 3. Remove both wheel and tire assemblies. 4. Remove the nuts that attach the tie rod ends to the steering knuckle. 5. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 6. Separate the intermediate steering shaft cover (boot) from the steering gear. 7. Remove the steering gear from the vehicle. 8. Transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 9. Remove the tie rod ends from the old steering gear. 10. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 11. Install the tie rod end on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 12. Install the new steering gear in the vehicle. 13. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 14. Install the steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 16. Install the heat shield to the steering gear and install the attaching bolts. Tighten the bolts to 14 Nm (124 lb in). 17. Reposition the stabilizer bar. 18. Install the left and right side stabilizer bar links to the lower control arm. Tighten the bolts to 23 Nm (17 lb ft). 19. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 20. Install the two rear engine cradle attaching bolts. Tighten the bolts to 165 Nm (122 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Install both wheel and tire assemblies. 23. Lower the vehicle. 24. From inside the vehicle, connect the intermediate steering shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 25. Install the driver's side insulator panel under the IP. 26. Add power steering fluid and bleed the system. 27. Check alignment and set toe-in as necessary. 28. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8535 Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 3. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 4. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 5. Remove the left and right side stabilizer bar links from the lower control arms. 6. Reposition the stabilizer bar as necessary to improve access to the steering gear. 7. Remove the two bolts that attach the steering gear to the engine cradle. 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the steering gear from the engine cradle mounting brackets and reposition to access the adjuster plug lock nut and the adjuster plug. Do not remove the plug. 11. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 12. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 13. Remove the lower retaining snap ring (1), Figure 3. Important Placement of a block of wood between the steering gear housing and the transmission case will help to support the steering gear in the next step. 14. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 15. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 16. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 17. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 18. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 19. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 20. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 21. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8536 Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 22. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 23. Install a new dust cap (2) to the steering gear housing. 24. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 25. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 26. Install the steering gear in the engine cradle mounting brackets. 27. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 28. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 180 Nm (133 lb ft). 29. Connect the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 48 Nm (35 lb ft). 30. Reposition the stabilizer bar. 31. Install the left and right side stabilizer bar links to the lower control arm. Tighten to 23 Nm (17 lb ft). 32. Lower the vehicle. 33. Check the power steering fluid and add if necessary. 34. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Remove the bolt and separate the intermediate steering shaft from the steering gear. 2. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 3. Remove the left and right side stabilizer bar links from the lower control arms. 4. Reposition the stabilizer bar as necessary to improve access to the steering gear. 5. Remove the two bolts that attach the steering gear to the engine cradle. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Loosen the outer tie rod end adjuster nuts. 8. Remove both wheel and tire assemblies. 9. Remove the nuts that attach the tie rod ends to the steering knuckles. 10. Using J-24319-B (outer tie rod end puller) or equivalent, separate the tie rod ends from the knuckles. 11. Disconnect the pressure and return lines from the steering gear. 12. On GT and GTP models, disconnect the electrical connector from the steering gear. 13. Remove the steering gear from the vehicle. 14. Remove the tie rod ends from the old steering gear. 15. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 16. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8537 17. Install the new steering gear in the engine cradle mounting brackets. 18. On GT and GTP models, connect the electrical connector for the steering gear. 19. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 20. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Raise the rear of the engine cradle and install the two rear attaching bolts. Tighten to 180 Nm (133 lb ft). 23. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten to 48 Nm (35 lb ft). 24. Reposition the stabilizer bar. 25. Install the left and right side stabilizer bar links to the lower control arms. Tighten to 23 Nm (17 lb ft). 26. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 27. Lower the vehicle. 28. Add power steering fluid and bleed the system. 29. Check the alignment and set toe-in as necessary. 30. Install the GM Recall Identification Label Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. 3. Remove the two bolts attaching the steering gear to the engine frame (cradle). 4. Release the brake pipe from the retainers at three locations on the engine cradle. 5. Remove the steering gear from the engine cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 6. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicle. 7. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8538 8. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 9. Remove the lower retaining snap ring (1), see Figure 3. 10. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 11. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 12. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 13. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 14. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 15. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 16. Place the bearing installer (1) JA4714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use extension JA4714-3 included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 17. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 18. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 19. Install a new dust cap (2) to the steering gear housing. 20. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 21. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 22. Reinstall the steering gear in the engine cradle mounting brackets. 23. Reattach the brake pipe to the retainers on the engine cradle. 24. Install the two bolts attaching the steering gear to the cradle. Tighten to 120 Nm (88 lb ft). 25. Lower the vehicle. 26. Check the power steering fluid level and add if necessary. 27. Install the GM Recall Identification Label. Steering Gear Replacement, If Required 1. Remove both wheel and tire assemblies. 2. Remove the nuts that attach the tie rod ends to the steering knuckle. 3. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 4. Support the rear of the engine frame (cradle) and remove the six rear attaching bolts. 5. Loosen the front cradle to body attaching bolts. Do not remove the bolts. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8539 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Remove the steering gear from the vehicle. 10. If necessary, transfer the mounting grommet(s) and bushing(s) from the old steering gear to the new steering gear. Note: The labor time allowance includes the time needed for transferring these parts. 11. Remove the tie rod ends from the old steering gear. 12. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 13. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 14. Install the new steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 120 Nm (88 lb ft). 16. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 17. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 18. Install the six rear engine cradle bolts. Tighten to 110 Nm (81 lb ft). 19. Tighten the front engine cradle to body bolts to 110 Nm (81 lb ft). 20. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 22 Nm (16 lb ft). 21. Reattach the brake pipe to the retainers on the engine cradle. 22. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 45 Nm (33 lb ft). 23. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 24. Lower the vehicle 25. Add power steering fluid and bleed the system. 26. Check the alignment and set toe-in as necessary. 27. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8540 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8541 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Recalls: > NHTSA02V286000 > Nov > 02 > Recall 02V286000: Steering Rack Defect Steering Gear: Recalls Recall 02V286000: Steering Rack Defect DEFECT: Certain passenger vehicles and minivans have lower pinion bearings in the power steering rack and pinion assembly in which the retainer tabs were not crimped properly. These and some other retainers could fail and permit the ball bearings to escape. If this occurs, the pinion shaft can be forced upward during left turns and back down as the steering wheel is moved back and to the right. If the pinion shaft moves further, the driver will need to exert more effort to turn the steering wheel, similar to a vehicle without power assisted steering. If the pinion shaft moves even further, the driver will require much higher effort to turn left and may not be able to turn the wheel as much as intended. With the maximum pinion shaft movement, which requires internal gear component damage, the driver can encounter high resistance to turning left, followed by unintended power assist to the right. In any of these conditions, a crash could occur. REMEDY: Dealers will install a new lower pinion bearing unless inspection of the existing bearing indicates that replacement of the gear assembly is necessary. The manufacturer has reported that owner notification began Jan. 17, 2003. Owners should contact Chevrolet at 1-800-222-1020, Pontiac at 1-8000-762-2737, or Oldsmobile at 1-800-442-6537. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation Technical Service Bulletin # 02049 Date: 030101 Recall - Steering Gear Lower Pinion Bearing Separation File In Section: Product Recalls Bulletin No.: 02049 Date: January, 2003 PRODUCT SAFETY RECALL SUBJECT: 02049 - POWER STEERING GEAR LOWER PINION BEARING SEPARATION MODELS: 1996-1998 CHEVROLET CAVALIER 1996 CHEVROLET LUMINA APV 1997-1998 CHEVROLET VENTURE 1996-1998 PONTIAC SUNFIRE, TRANS SPORT 1997-1998 PONTIAC GRAND PRIX 1996-1998 OLDSMOBILE SILHOUETTE CONDITION General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Pontiac Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles. Some of these vehicles have a condition where the lower pinion bearing in the power steering gear may separate. Most reports indicate the driver experienced an intermittent loss of power steering assist when making left turns, usually at low speeds. Power assist is normal in right hand turns. When trying to turn left, some drivers could experience higher resistance or, in a few cases, assist towards the right. If this happens while the vehicle is moving, a crash could result. CORRECTION Dealers are to inspect the condition of the lower pinion bearing and replace the lower pinion bearing, or in a few cases, replace the rack and pinion steering gear assembly. VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8551 Involved are certain 1996-1998 Chevrolet Cavalier; 1996 Chevrolet Lumina APV; 1997-1998 Chevrolet Venture; 1996-1998 Pontiac Sunfire, Trans Sport; 1997-1998 Grand Prix; and 1996-1998 Oldsmobile Silhouette vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of parts required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of January 13, 2003. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8552 CSO = Customer Special Order. SPECIAL TOOL Beginning the week of December 23, 2002, each dealer will be shipped a Power Steering Pinion Bearing Replacer, J44714-A, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-GM-TOOLS (1-800-468-6657). RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering. CUSTOMER REIMBURSEMENT Customer requests for reimbursement of previously paid repairs to replace the power steering gear lower pinion bearing or steering gear due to lower pinion bearing separation are to be submitted by January 31, 2004 (this time limit may be longer depending on the law in your state/province/country). All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following. - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s), a description of the repair, and the person or entity performing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8553 the repair. Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. CUSTOMER NOTIFICATION - For US and CANADA Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8554 Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter is shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Information Important If a vehicle has had the power steering gear lower pinion bearing or steering gear replaced prior to this recall, the applicable service procedures shown will still need to be performed on the vehicle. 1996 Lumina APV, Trans Sport, and Silhouette Lower Pinion Bearing Inspection (Includes Steering Gear Replacement, If Required) Because of limited access in this vehicle, the pinion bearing can only be inspected after the steering gear has been removed from the vehicle. For additional information on steering gear removal and bleeding the system, see the steering section of the appropriate service manual. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Remove both wheel and tire assemblies. 6. Remove the cotter pins and nuts from both outer tie rod ends. 7. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8555 8. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 11. Disconnect the pressure and return lines from the steering gear. 12. Remove the two bolts that attach the steering gear to the engine cradle 13. Separate the intermediate steering shaft cover (boot) from the steering gear. 14. Remove the steering gear from the vehicle. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 15. On a suitable work surface, remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to step 31 and replace the complete steering gear assembly. 16. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 17. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8556 18. Remove the lower retaining snap ring (1), see Figure 3. 19. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 20. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8557 21. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 22. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. 23. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 24. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 25. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. Lightly tap with a hammer until the bearing is seated in the housing. 26. Install a new snap ring. When properly installed, the large lug (1) on the snap ring must be on the right side as shown in Figure 9. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8558 27. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft) 28. Install a new dust cap (2) to the steering gear housing. 29. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 30. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 31. If installing a new steering gear, transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 32. If installing a new steering gear, remove the tie rod ends from the old steering gear. 33. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 34. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 30 Nm (22 lb ft) plus 120 degrees (or 2 flats of the nut). 35. Install the steering gear to the engine cradle in the vehicle. 36. Install the two bolts attaching the steering gear to the cradle. Tighten to 80 Nm (59 lb ft). 37. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 38. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 39. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 165 Nm (122 lb ft). 40. Reposition the intermediate steering shaft cover (boot) and attach to the steering gear. 41. Connect the outer tie rod ends to the steering knuckles and install the nuts. Tighten the nuts to 10 Nm (88 lb in) and then tighten the nuts an additional 180 degrees (1/2 turn). If necessary, rotate (tighten) the nuts to align the hole and install the cotter pins. 42. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 43. Lower the vehicle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8559 44. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 45. Install the driver's side insulator panel under the IP. 46. Add power steering fluid as necessary and bleed the system 47. Check alignment and set toe-in as necessary. 48. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. From inside the vehicle, remove the driver's side insulator panel from under the instrument panel (IP). 2. Disconnect the intermediate steering shaft from the steering column. 3. Open the hood. 4. Raise the vehicle on a suitable hoist and support. 5. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 6. Lower the rear of the engine cradle as necessary to access steering gear. 7. Remove the left and right side stabilizer bar links from the lower control arms. 8. Reposition the stabilizer bar to improve access to the steering gear. 9. Remove the bolts attaching the heat shield to the steering gear and remove the shield. 10. Remove the two bolts that attach the steering gear to the engine cradle. 11. Remove the steering gear from the cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 12. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 13. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 14. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 15. Remove the lower remaining snap ring (1), see Figure 3. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8560 16. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 17. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 18. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6 Finger tighten the forcing screw to push the puller legs against the bearing. 19. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 20. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 21. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 22. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 23. Install a new snap ring, Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 24. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 25. Install a new dust cap (2) to the steering gear housing. 26. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 27. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 28. Reinstall the steering gear in the engine cradle mounting brackets. 29. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 30. Install the heat shield to the steering gear and install the attaching bolts. Tighten to 14 Nm (124 lb in). 31. Reposition the stabilizer bar. 32. Install the left and right side stabilizer bar links to the lower control arms. Tighten the bolts to 23 Nm (17 lb ft). 33. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 34. Install the two rear engine cradle attaching bolts. Tighten to 165 Nm (122 lb ft). 35. Lower the vehicle 36. From inside the vehicle, connect the intermediate shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 37. Install the driver's side insulator panel under the IP. 38. Check the power steering fluid and add if necessary. 39. Check alignment and set toe-in as necessary. 40. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8561 2. Loosen the outer tie rod adjuster nuts. 3. Remove both wheel and tire assemblies. 4. Remove the nuts that attach the tie rod ends to the steering knuckle. 5. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 6. Separate the intermediate steering shaft cover (boot) from the steering gear. 7. Remove the steering gear from the vehicle. 8. Transfer the intermediate steering shaft from the old steering gear to the new steering gear. Tighten the bolt to 48 Nm (35 lb ft). 9. Remove the tie rod ends from the old steering gear. 10. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 11. Install the tie rod end on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 12. Install the new steering gear in the vehicle. 13. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 14. Install the steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten the bolts to 80 Nm (59 lb ft). 16. Install the heat shield to the steering gear and install the attaching bolts. Tighten the bolts to 14 Nm (124 lb in). 17. Reposition the stabilizer bar. 18. Install the left and right side stabilizer bar links to the lower control arm. Tighten the bolts to 23 Nm (17 lb ft). 19. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 20. Install the two rear engine cradle attaching bolts. Tighten the bolts to 165 Nm (122 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Install both wheel and tire assemblies. 23. Lower the vehicle. 24. From inside the vehicle, connect the intermediate steering shaft to the steering column. Tighten the bolt to 48 Nm (35 lb ft). 25. Install the driver's side insulator panel under the IP. 26. Add power steering fluid and bleed the system. 27. Check alignment and set toe-in as necessary. 28. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8562 Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 3. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicles. 4. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 5. Remove the left and right side stabilizer bar links from the lower control arms. 6. Reposition the stabilizer bar as necessary to improve access to the steering gear. 7. Remove the two bolts that attach the steering gear to the engine cradle. 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Lower the rear of the engine cradle as necessary to access the steering gear. 10. Remove the steering gear from the engine cradle mounting brackets and reposition to access the adjuster plug lock nut and the adjuster plug. Do not remove the plug. 11. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 12. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 13. Remove the lower retaining snap ring (1), Figure 3. Important Placement of a block of wood between the steering gear housing and the transmission case will help to support the steering gear in the next step. 14. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 15. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 16. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 17. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 18. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 19. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 20. Place the bearing installer (1) J-44714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use the extension included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 21. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8563 Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 22. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 23. Install a new dust cap (2) to the steering gear housing. 24. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 25. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 26. Install the steering gear in the engine cradle mounting brackets. 27. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 28. Raise the rear of the engine cradle and install the rear attaching bolts. Tighten to 180 Nm (133 lb ft). 29. Connect the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 48 Nm (35 lb ft). 30. Reposition the stabilizer bar. 31. Install the left and right side stabilizer bar links to the lower control arm. Tighten to 23 Nm (17 lb ft). 32. Lower the vehicle. 33. Check the power steering fluid and add if necessary. 34. Install the GM Recall Identification Label. Steering Gear Replacement, If Required For additional information on steering gear removal, see the steering section in the appropriate service manual. 1. Remove the bolt and separate the intermediate steering shaft from the steering gear. 2. Support the rear of the engine frame (cradle) and remove the two rear attaching bolts. 3. Remove the left and right side stabilizer bar links from the lower control arms. 4. Reposition the stabilizer bar as necessary to improve access to the steering gear. 5. Remove the two bolts that attach the steering gear to the engine cradle. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Loosen the outer tie rod end adjuster nuts. 8. Remove both wheel and tire assemblies. 9. Remove the nuts that attach the tie rod ends to the steering knuckles. 10. Using J-24319-B (outer tie rod end puller) or equivalent, separate the tie rod ends from the knuckles. 11. Disconnect the pressure and return lines from the steering gear. 12. On GT and GTP models, disconnect the electrical connector from the steering gear. 13. Remove the steering gear from the vehicle. 14. Remove the tie rod ends from the old steering gear. 15. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 16. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8564 17. Install the new steering gear in the engine cradle mounting brackets. 18. On GT and GTP models, connect the electrical connector for the steering gear. 19. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 80 Nm (59 lb ft). 20. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 21. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 30 Nm (22 lb ft), plus 120 degrees (or 2 flats of the nut). 22. Raise the rear of the engine cradle and install the two rear attaching bolts. Tighten to 180 Nm (133 lb ft). 23. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten to 48 Nm (35 lb ft). 24. Reposition the stabilizer bar. 25. Install the left and right side stabilizer bar links to the lower control arms. Tighten to 23 Nm (17 lb ft). 26. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 27. Lower the vehicle. 28. Add power steering fluid and bleed the system. 29. Check the alignment and set toe-in as necessary. 30. Install the GM Recall Identification Label Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Lower Pinion Bearing Inspection The following service procedure is for inspection of the lower pinion bearing and can be performed without completely removing the steering gear from the vehicle. Important Tool J-44714-A is required to perform this service procedure. 1. Open the hood. 2. Raise the vehicle on a suitable hoist and support. 3. Remove the two bolts attaching the steering gear to the engine frame (cradle). 4. Release the brake pipe from the retainers at three locations on the engine cradle. 5. Remove the steering gear from the engine cradle mounting brackets and reposition to access the lower pinion shaft dust cap. Important When removing the dust cap in the next step, watch for loose ball bearings that may have separated from the inner and outer pinion bearing races. 6. Remove the dust cap (3) from the steering gear housing (2) and inspect for loose ball bearings, see Figure 1. ^ If no ball bearings were found in the dust cap, proceed to the next step and replace the lower pinion bearing. ^ If one or more ball bearings were found loose in the dust cap, proceed to the section in this recall bulletin titled "Steering Gear Replacement" for the described vehicle. 7. Loosen the adjuster plug lock nut (3) and the adjuster plug (2), see Figure 2. Do not remove the plug. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8565 8. While holding the stub shaft (1), remove the retaining nut (4) from the pinion shaft, see Figure 1. Do not reuse the nut. 9. Remove the lower retaining snap ring (1), see Figure 3. 10. Carefully insert the legs (1) of pinion bearing remover J-44714-1 (included in J-44714-A) between the balls in the lower pinion bearing, see Figure 4. 11. Assemble the center bolt (2) into the forcing screw (1) of the tool, see Figure 5. Back the center bolt at least 25 mm (1 in) inside the forcing screw. 12. Assemble the forcing screw (2) inside the puller legs (1), see Figure 6. Finger tighten the forcing screw to push the puller legs against the bearing. 13. Using a 24 mm wrench to hold the forcing screw, use a 17 mm socket to tighten the center bolt until the bearing is removed from the gear housing, see Figure 7. Do not reuse the bearing. Important Inspect the gear housing to ensure that no parts of the old bearing remain. 14. Apply a small quantity of lubrication inside the housing bore where the new bearing will be installed. 15. Center the new bearing over the pinion thread. The bearing can be installed with either side facing outwards. 16. Place the bearing installer (1) JA4714-2 (included in J-44714-A) over the pinion thread, see Figure 8. If necessary, use extension JA4714-3 included with the installer. Lightly tap with a hammer until the bearing is seated in the housing. 17. Install a new snap ring, see Figure 9. When properly installed, the large lug (1) on the snap ring must be on the right side as shown. Important If the stub shaft is not held in the next step, damage to the pinion teeth will occur. 18. While holding the stub shaft (1) install a new retaining nut (3) on the pinion shaft, see Figure 10. Tighten to 30 Nm (22 lb ft). 19. Install a new dust cap (2) to the steering gear housing. 20. With the rack centered in the housing, tighten the adjuster plug (2) to 10 Nm (88 lb in), then back off 40 to 50 degrees (4), see Figure 11. Check the torque on the pinion. Maximum pinion preload torque is 4 Nm (35 lb in). 21. Tighten the adjuster plug lock nut (3) firmly against the steering gear housing while holding the adjuster plug (2) stationary. 22. Reinstall the steering gear in the engine cradle mounting brackets. 23. Reattach the brake pipe to the retainers on the engine cradle. 24. Install the two bolts attaching the steering gear to the cradle. Tighten to 120 Nm (88 lb ft). 25. Lower the vehicle. 26. Check the power steering fluid level and add if necessary. 27. Install the GM Recall Identification Label. Steering Gear Replacement, If Required 1. Remove both wheel and tire assemblies. 2. Remove the nuts that attach the tie rod ends to the steering knuckle. 3. Using J-24319-B (outer tie rod end puller) or equivalent, separate both tie rod ends from the steering knuckles. 4. Support the rear of the engine frame (cradle) and remove the six rear attaching bolts. 5. Loosen the front cradle to body attaching bolts. Do not remove the bolts. 6. Lower the rear of the engine cradle as necessary to access the steering gear. 7. Disconnect the pressure and return lines from the steering gear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8566 8. Remove the bolt and separate the intermediate steering shaft from the steering gear. 9. Remove the steering gear from the vehicle. 10. If necessary, transfer the mounting grommet(s) and bushing(s) from the old steering gear to the new steering gear. Note: The labor time allowance includes the time needed for transferring these parts. 11. Remove the tie rod ends from the old steering gear. 12. Measure the position of the adjuster nuts on the old steering gear and adjust the new nuts on the new steering gear to the same measurement. 13. Install the tie rod ends on the new steering gear and tighten the adjuster nuts to 68 Nm (50 lb ft). 14. Install the new steering gear in the engine cradle mounting brackets. 15. Install the two bolts that attach the steering gear to the engine cradle. Tighten to 120 Nm (88 lb ft). 16. Connect the pressure and return lines to the steering gear. Tighten to 27 Nm (20 lb ft). 17. Raise the rear of the engine cradle while aligning the intermediate steering shaft. 18. Install the six rear engine cradle bolts. Tighten to 110 Nm (81 lb ft). 19. Tighten the front engine cradle to body bolts to 110 Nm (81 lb ft). 20. Install the intermediate steering shaft to the steering gear and install the bolt. Tighten the bolt to 22 Nm (16 lb ft). 21. Reattach the brake pipe to the retainers on the engine cradle. 22. Install the tie rod ends to the steering knuckles. Install the retaining nuts and tighten to 45 Nm (33 lb ft). 23. Install both wheel and tire assemblies. Tighten the lug nuts to 140 Nm (103 lb ft). 24. Lower the vehicle 25. Add power steering fluid and bleed the system. 26. Check the alignment and set toe-in as necessary. 27. Install the GM Recall Identification Label. Important For U.S. and Canada: All replaced steering gears are to be held until a return request is received from the GM Warranty Parts Center (WPC). For additional information, refer to service bulletin # 99-00-89-19B, issued February 2002. DO NOT RETURN REPLACED STEERING GEARS TO GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8567 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 02049 > Jan > 03 > Recall - Steering Gear Lower Pinion Bearing Separation > Page 8568 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > NHTSA02V286000 > Nov > 02 > Recall 02V286000: Steering Rack Defect Steering Gear: All Technical Service Bulletins Recall 02V286000: Steering Rack Defect DEFECT: Certain passenger vehicles and minivans have lower pinion bearings in the power steering rack and pinion assembly in which the retainer tabs were not crimped properly. These and some other retainers could fail and permit the ball bearings to escape. If this occurs, the pinion shaft can be forced upward during left turns and back down as the steering wheel is moved back and to the right. If the pinion shaft moves further, the driver will need to exert more effort to turn the steering wheel, similar to a vehicle without power assisted steering. If the pinion shaft moves even further, the driver will require much higher effort to turn left and may not be able to turn the wheel as much as intended. With the maximum pinion shaft movement, which requires internal gear component damage, the driver can encounter high resistance to turning left, followed by unintended power assist to the right. In any of these conditions, a crash could occur. REMEDY: Dealers will install a new lower pinion bearing unless inspection of the existing bearing indicates that replacement of the gear assembly is necessary. The manufacturer has reported that owner notification began Jan. 17, 2003. Owners should contact Chevrolet at 1-800-222-1020, Pontiac at 1-8000-762-2737, or Oldsmobile at 1-800-442-6537. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench Steering Gear: All Technical Service Bulletins Tools - Adjuster Locknut Wrench File In Section: 3 - Steering/Suspension Bulletin No.: 83-32-10 Date: November, 1998 INFORMATION Subject: Essential Tool J 43435 Adjuster Locknut Wrench Models: 1990-99 Passenger Cars and Trucks with Integral Power Steering A new essential tool, J 43435 Adjuster Locknut Wrench, has been sent to all GM Dealers. This tool should be used on all Integral power steering gears, both past and current models. The following procedure should be used In place of existing Service Manual procedures for Coupling Shield and Locknut Removal and Replacement. The correct adjustment procedure and use of the essential tools are critical to restore the vehicle "On Center" feel (See Figure 1). Important: Coupling shield retainer and locknut assembly replacement procedures require the following special tools: J 42882 Adjuster Nut Wrench J 43435 Adjuster Locknut Wrench Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench > Page 8577 (See Figure 2) Procedure 1. Place J 42882 over the end of the stub shaft. Place J 43435 over the end. J 43435 is reversible and can be used with both old and new style coupling shield retainers and locknuts. 2. Tighten the coupling shield retainer and locknut assembly after an adjustment or repair has been made to the power steering gear to the specified torque (See Figure 3). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench Steering Gear: All Technical Service Bulletins Tools - Adjuster Locknut Wrench File In Section: 3 - Steering/Suspension Bulletin No.: 83-32-10 Date: November, 1998 INFORMATION Subject: Essential Tool J 43435 Adjuster Locknut Wrench Models: 1990-99 Passenger Cars and Trucks with Integral Power Steering A new essential tool, J 43435 Adjuster Locknut Wrench, has been sent to all GM Dealers. This tool should be used on all Integral power steering gears, both past and current models. The following procedure should be used In place of existing Service Manual procedures for Coupling Shield and Locknut Removal and Replacement. The correct adjustment procedure and use of the essential tools are critical to restore the vehicle "On Center" feel (See Figure 1). Important: Coupling shield retainer and locknut assembly replacement procedures require the following special tools: J 42882 Adjuster Nut Wrench J 43435 Adjuster Locknut Wrench Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 83-32-10 > Nov > 98 > Tools - Adjuster Locknut Wrench > Page 8583 (See Figure 2) Procedure 1. Place J 42882 over the end of the stub shaft. Place J 43435 over the end. J 43435 is reversible and can be used with both old and new style coupling shield retainers and locknuts. 2. Tighten the coupling shield retainer and locknut assembly after an adjustment or repair has been made to the power steering gear to the specified torque (See Figure 3). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications Steering Gear: Mechanical Specifications Hose Fitting Specifications Power Steering Gear: Hose Fitting Nut ................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) CYL Line Fitting .................................................... .............................................................................................................................. 27 Nm (20 ft. lbs.) Power Steering Gear Cylinder End Fittings ........................................................................................................................... .................................................. 27.0 Nm (20 ft. lbs.) Hex Lock Nut ................................................... ..................................................................................................................................... 30.0 Nm (22 ft. lbs.) Hex Torque Prevailing Nut (outer tie rod) .............................................................................................................................. 10.0 Nm (7 ft. lbs.) plus 210° Inner Tie Rod ....................................................................................................................................... ................................................ 100.0 Nm (74 ft. lbs.) Jam Nut ............................................................ ...................................................................................................................................... 68.0 Nm (50 ft. lbs.) Lock Nut ................................................................................................................................... ............................................................. 68.0 Nm (50 ft. lbs.) Pinion Preload ....................................... ............................................................................................................................................... 1.8 Nm (16 inch lbs.) Valve End Fittings .......................................................................................................... .................................................................... 16.9 Nm (12.6 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications > Page 8586 Steering Gear: Capacity Specifications Capacity Complete System ................................................................................................................. ................................................ 0.75 liter (1-1/2 pints) Lubricant ......................................................................................................................................................... Power Steering Fluid 1050017 or Equivalent Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8587 Steering Gear: Service Precautions NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also can out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8588 Steering Gear: Description and Operation The power rack and pinion steering system has a rotary control valve which directs hydraulic fluid coming from the hydraulic pump to one side or the other side of the rack piston. The integral rack piston is attached to the rack. The rack piston converts hydraulic pressure to a linear force which moves the rack left or right. The force is then transmitted through the inner and outer tie rods to the struts which turn the wheels. If hydraulic assist is not available, manual control will be maintained, however, more steering effort will be required. The movement of the steering wheel is transferred to the pinion. The movement of the pinion is then transferred through the pinion teeth, which mesh with teeth on the rack, causing the rack to move. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Diagnostic Information & Procedures Steering Gear: Testing and Inspection Diagnostic Information & Procedures GENERAL PROCEDURE Inspect for: ^ Overfilled reservoir. ^ Fluid aeration and overflow. ^ Hose connections. ^ Verify exact point of leakage. Example: The point from which the fluid is dripping is not necessarily the point where the system is leaking. Fluid overflowing from the reservoir may appear to be dripping from the bottom of the housing. Important: When service is required: A. Clean leakage area upon disassembly. B. Replace leaking seal. C. Check component sealing surfaces for damage. D. Reset bolt tightening specification, where required. Important: Some complaints about the power steering system may be reported as: A. Fluid leakage on garage floor. B. Fluid leaks visible on steering gear or pump. C. Growling noise, especially when parking or when engine is cold. D. Loss of power steering when parking. E. Heavy steering effort. ^ When troubleshooting these kinds of complaints, check for an external leak in the power steering system. EXTERNAL LEAKAGE CHECK Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Diagnostic Information & Procedures > Page 8591 The purpose of this procedure is to pinpoint the location of the leak. In some cases, the leak can easily be located. But, seepage-type leaks may be more difficult to isolate. To locate seepage leaks, use the following method. 1. With the engine off, wipe dry the complete power steering system. 2. Check the fluid level in the pump's reservoir. Adjust fluid level as necessary. 3. Start the engine, then turn the steering wheel from stop to stop several times. Do not hold it at a stop for any length of time, as this can damage the power steering pump. It is easier if someone else operates the steering wheel while you search for the seepage. 4. Find the exact area of the leak and repair leak. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Diagnostic Information & Procedures > Page 8592 Steering Gear: Testing and Inspection Diagnosis By Symptom HISSING NOISE There is some noise in all power steering systems. One of the most common is a hissing sound when the steering wheel is turned and the vehicle is not moving. This noise will be most evident when turning the wheel while the brakes are applied. There is no relationship between this noise and steering performance. Do not replace the valve and pinion unless the "hissing" noise is extremely objectionable. A replacement valve and pinion will also have a slight noise, and is not always a cure for the condition. Check that the intermediate shaft joints are not loose. RATTLE OR CHUCKING NOISE Inspect for: ^ Power steering hose or line grounding out. ^ Tie rod ends loose. ^ Loose steering gear mounting. ^ Rack bearing preload loose. ^ Intermediate shaft boot mispositioned. POOR RETURN OF STEERING WHEEL TO CENTER Inspect for: ^ Front-wheel alignment. ^ Hub and bearing assembly worn. ^ Intermediate shaft binding or loose. ^ Tie rod end binding. ^ Ball joint binding. ^ Tight or frozen steering shaft bearings. ^ Rack bearing preload. ^ Sticky or plugged valve and pinion. ^ Intermediate shaft boot mispositioned. MOMENTARY INCREASE IN EFFORT WHEN TURNING WHEEL FAST TO RIGHT OR LEFT (ESPECIALLY WHEN COLD) Inspect for: ^ High internal leakage in gear or pump. ^ Hose pinched or restricted. ^ Sticking flow control valve. ^ Low fluid level in pump reservoir. STEERING WHEEL SURGES OR JERKS WHEN TURNING WITH ENGINE RUNNING (ESPECIALLY DURING PARKING, OR COLD) Inspect for: ^ Belt slipping. ^ Insufficient pump pressure. EXCESSIVE WHEEL KICKBACK OR LOOSE STEERING Inspect for: ^ Air in system. ^ Steering gear attachments loose. ^ Intermediate shaft loose. ^ Tie rod ends loose. ^ Hub and bearing assembly worn. ^ Rack bearing preload. HARD STEERING OR LACK OF ASSIST (ESPECIALLY DURING PARKING) Inspect for: ^ Loose or worn intermediate shaft. ^ Loose belt. ^ Insufficient pump pressure. ^ High internal leakage in gear or pump. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations Steering Gear: Service and Repair Seal Replacement Recommendations Lip seals, which seal rotating shafts, require special treatment. This type of seal is used on the steering gear at the valve and pinion and on the drive shaft of the pump. When there is a leak in one of these areas, always replace the seal(s), after inspecting and thoroughly cleaning the sealing surfaces. Replace the shaft only if very severe pitting is found. If the corrosion in the lip seal contact zone is slight, clean the surface of the shaft with crocus cloth. Replace the shaft only if the leakage cannot be stopped by first smoothing with crocus cloth. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8595 Steering Gear: Service and Repair On-Vehicle Service Steering Gear Replacement ^ Tool Required: J 24319-01 Steering Linkage Puller - Or Equivalent REMOVE OR DISCONNECT 1. Left sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8596 2. Upper pinch bolt on intermediate shaft assembly. 3. Line retainer (if applicable). 4. Raise vehicle. 5. Left front tire and wheel assembly. 6. Tie rod ends from struts using J 24319-01. 7. Left and right mounting bolts. 8. Gear inlet and outlet hose assemblies from rack and pinion steering gear. 9. Lower pinch bolt from flange inter-shaft assembly. 10. Inter-shaft assembly. 11. Loosen (2) rear and loosen (4) remaining crossmember bolts, to provide removal clearance. 12. Rack and pinion through left wheel opening. INSTALL OR CONNECT 1. Rack and pinion through left wheel opening. 2. Install (2) rear and (4) remaining crossmember bolts. ^ Tighten: Left rear outboard, first to 130 Nm (96 ft. lbs.). - Right rear outboard, second to 130 Nm (96 ft. lbs.). - Front upper bolts third to 130 Nm (96 ft. lbs.). - Rear inboard bolts last to 130 Nm (96 ft. lbs.). 3. Flange and inter-shaft lower pinch bolt. ^ Tighten lower pinch bolt to 41 Nm (30 ft. lbs.). 4. Gear inlet and outlet pipes to rack and pinion steering gear. ^ Tighten power steering lines to 27 Nm (20 ft. lbs.). 5. Power steering gear bolts, hand start bolts and nuts. Tighten left side bolt and nuts to specification first, then tighten right side bolt and nut to specification. ^ Tighten power steering gear bolts to 120 Nm (89 ft. lbs.). 6. Raise vehicle. 7. Tie rod ends to struts and cotter pins after tightening nuts to specifications. ^ Tighten tie rod end bolts to 50 Nm (37 ft. lbs.). 8. Left front tire and wheel assembly and tighten to specification. 9. Line retainer, if applicable. 10. Lower vehicle. 11. Steering column upper pinch bolt. ^ Tighten upper pinch bolt to 41 Nm (30 ft. lbs.). 12. Left sound insulator. 13. Fill with fluid and bleed air from system. 14. Check toe setting and adjust as required. ^ Inspect for leaks. Gear Inlet Hose Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8597 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8598 REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear inlet hose from pump. 4. Raise vehicle. 5. Gear inlet hose from steering gear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8599 INSTALL OR CONNECT 1. Route new gear inlet hose to steering gear. 2. Gear inlet hose to steering gear. 3. Lower vehicle. 4. Install gear inlet hose to pump. ^ Tighten gear inlet hose assembly to 27 Nm (20 ft. lbs.). 5. Fill and bleed power steering system. ^ Bleed air from system. Gear Outlet Hose Replacement Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8600 REMOVE OR DISCONNECT 1. Position rags under pump to absorb oil. 2. Siphon fluid from reservoir. 3. Gear outlet hose from pump after sliding spring clamp back. 4. Line retainer (if applicable). 5. Gear inlet hose assembly from rack and pinion steering gear. 6. Gear outlet hose assembly from rack and pinion steering gear. 7. Gear outlet pipe and/or hose from vehicle. INSTALL OR CONNECT 1. Gear outlet hose assembly into position on vehicle. 2. Gear outlet hose assembly to rack and pinion steering gear. Tighten outlet hose assembly to 27 Nm (20 ft. lbs.). 3. Gear inlet hose assembly to rack and pinion steering gear. Tighten hose assembly to 27 Nm (20 ft. lbs.). 4. Line retainer (if applicable). 5. Gear outlet hose to pump and hose clamp. Important: Fill and Bleed air from system. 6. Inspect for leaks. Seal Replacement Lip seals, which seal rotating shafts, require special treatment. This type of seal is used on the steering gear at the pinion shaft and on the drive shaft of the pump. When a leak occurs in this area, always replace the seal after inspecting and thoroughly cleaning the sealing surface. Replace the shaft only if very severe pitting is found. If the corrosion in the lip seal contact zone is slight, clean the surface of the shaft with crocus cloth. Replace the shaft only if the leakage cannot be stopped by smoothing with crocus cloth first. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8601 Steering Gear: Service and Repair Unit Repair Boot or Rack Guide Fig. 24 Exploded View Of Power Rack & Pinion Assembly 1. Cut off righthand mounting grommet and boot clamps, Fig. 24. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8602 2. Slide boot retaining bushing from rack and pinion boot. 3. Slide boot assembly from rack and pinion housing. 4. Remove insert and rack guide assembly as necessary. 5. Slide boot retaining bushing from rack and pinion boot. 6. Slide new boot clamp onto rack and pinion boot. 7. Insert boot retaining bushing into rack and pinion boot. 8. Coat inner lip of boot retaining bushing lightly with suitable grease to facilitate assembly, then slide assembly onto housing assembly. 9. Ensure center housing cover washers are in place on rack and pinion boot. 10. For ease of assembly, insert inner tie rod bolt through center housing cover washers, insert and rack guide and lightly thread bolt into rod and rack assembly to keep components in proper alignment. 11. Place boot retaining bushing onto cylinder tube of rack and pinion assembly, then slide into end of rack and pinion boot. 12. Slide boot clamp over cylinder end of housing and position on rack and pinion boot. 13. Slide rack and pinion boot and boot retaining bushing until seated in bushing groove in housing. 14. Position boot clamp on rack and pinion boot and crimp clamp. 15. Position bridge of boot clamp over split in boot retaining bushing and crimp clamp. Bridge of boot clamp must be crimped over split in boot retaining bushing to ensure proper sealing. Pinion Seal, Dust Seal and Bearing/Annulus Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8603 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8604 ^ Tools Required: J 29810 Stub Shaft Seal Protector, Or Equivalent - 14 mm Crowfoot Wrench Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8605 REMOVE OR DISCONNECT 1. Rack and pinion steering assembly from vehicle). 2. Adjuster plug lock nut (15) from adjuster plug. 3. Adjuster plug from gear assembly (30). 4. Adjuster spring and rack bearing. 5. Retaining ring (17) from valve bore of gear assembly (30). 6. Dust cover (33) from bottom of gear assembly (30). NOTICE: Stub shaft must be held to prevent damage to the pinion teeth. 7. Hex lock nut (32) from lower end of pinion and valve assembly, while holding stub shaft with 14 mm Crowfoot Wrench. NOTICE: DO NOT hammer or pound on pinion and valve assembly. This will cause damage or loosen the drive pin. Important: When performing the following procedure, do not remove pinion and valve assembly from gear assembly. Press pinion and valve assembly only far enough to allow removal of bearing/annulus and seal. Pinion and valve assembly removal is not required. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8606 8. Use an arbor press. Press on threaded end of pinion until it is possible to remove stub shaft, spool shaft seal (20), and stub shaft bearing/annulus assembly (21). INSTALL OR CONNECT NOTICE: If the stub shaft is not held, damage to the pinion teeth will occur. 1. Hex lock nut (32) onto pinion, while holding the valve stub shaft. ^ Tighten hex lock nut (32) to 30 Nm (22 ft. lbs.). 2. Dust cover (33) to gear assembly (30). 3. Stub shaft bearing annulus assembly (21) onto valve stub shaft. 4. Seal protector J 29810 onto valve stub shaft. 5. Apply a small quantity of grease on seal (20). ^ Spool shaft seal (20) over protector and into gear assembly (30). 6. Retaining ring (17) into groove in gear assembly (30). 7. Lubricate stub shaft and dust seal area with grease. 8. Coat rack bearing, adjuster spring and adjuster plug with lithium base grease and install in gear assembly (30). ^ With rack centered in the gear assembly (30), turn adjuster plug clockwise until it bottoms in the gear assembly, then back off 50° to 70° (approx. one flat). Check rotational torque on pinion. Maximum pinion preload torque is 1.8 Nm (16 inch lbs.). 9. Adjuster plug lock nut (15) to adjuster plug. Tighten firmly against gear assembly while holding adjuster plug stationary. ^ Tighten lock nut (15) to 68 Nm (50 ft. lbs.) while holding adjuster plug stationary. 10. Rack and pinion assembly into vehicle. Important: Flush power steering system (hoses, reservoir and cooler lines) with power steering fluid - GM Part #1050017 (or equivalent meeting GM Specification #9985010), refer to "Flushing And Bleeding Procedures." Outer Tie Rod Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8607 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8608 ^ Tool Required: J 24319-01 Universal Steering Linkage Puller - Or Equivalent REMOVE OR DISCONNECT 1. Hex torque prevailing nut (1) from outer tie rod assembly (5). 2. Loosen jam nut (7). 3. Outer tie rod (5) from steering knuckle with J 24319-01. 4. Outer tie rod (5) from inner tie rod (12). INSTALL OR CONNECT 1. Outer tie rod assembly (5) to inner tie rod (12). Do not tighten jam nut (7). 2. Outer tie rod (5) to steering knuckle, hex torque prevailing nut (1) to outer tie rod stud. ^ Tighten: Hex torque prevailing nut (1) to 10 Nm (7 ft. lbs.). - Tighten nut an additional 210° of rotation. ^ Adjust toe by turning inner tie rod (12). Important: Be sure rack and pinion boot (10) is not twisted or puckered during toe adjustment. ^ Tighten jam nut (7) against outer tie rod (5) to 68 Nm (50 ft. lbs.). Inner Tie Rod Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8609 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8610 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8611 REMOVE OR DISCONNECT 1. Rack and pinion assembly from vehicle. 2. Do all steps of RACK & PINION BOOT and BREATHER TUBE, under "REMOVE OR DISCONNECT. 3. Shock dampener (13) from inner tie rod assembly (12) and slide back on rack. NOTICE: Rack must be held during removal of inner tie rod (12) to prevent rack damage. 4. Inner tie rod assembly (12) from rack assembly as follows. ^ Place a wrench on flat of rack assembly. ^ Place another wrench on flats of inner tie rod housing. ^ Rotate inner tie rod housing counterclockwise until inner tie rod (12) separates from rack. INSTALL OR CONNECT Important: Rack must be held during inner tie rod (12) installation to prevent internal gear damage. 1. Shock dampener (13) onto rack. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8612 2. Inner tie rod (12) on rack. ^ Place a wrench on flat of rack assembly. ^ Place another wrench on flats of inner tie rod housing. ^ Tighten inner tie rod (12) to 100 Nm (74 ft. lbs.). Important: Make sure tie rod rocks freely in housing before staking inner tie rod assembly (12) to rack. 3. Support rack and housing of inner tie rod assembly (12) and stake both sides of inner tie rod housing to flats on rack. ^ Check both stakes by inserting a 0.25 mm (.010 in.) feeler gauge between rack and tie rod housing. Feeler must not pass between rack and housing stake. 4. Slide shock dampener (13) over inner tie rod housing until it engages. 5. Do all steps of RACK & PINION BOOT and BREATHER TUBE, under "INSTALL OR CONNECT." 6. Rack and pinion assembly to vehicle. Cylinder Line Assembly and O-Ring Seals Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8613 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8614 ^ Tools Required: 12mm Flare Nut Wrench - 16mm Flare Nut Wrench REMOVE OR DISCONNECT 1. Loosen cylinder line fittings (25) or (26) on cylinder end of gear assembly (30). 2. Loosen fittings on cylinder line assemblies (25) or (26) at valve end of gear assembly (30). 3. Cylinder line assemblies (25) or (26) from rack and pinion gear assembly (30). 4. O-ring seals (23) from valve end of lines (25) or (26) and discard. INSTALL OR CONNECT Inspect lines for: ^ Cracks. ^ Dents. ^ Damage to threads. ^ Replace as needed. 1. New O-ring seals (23) to valve end of lines (25) or (26). 2. Cylinder line assemblies (25) or (26) to gear assembly (30). NOTICE: Carefully align threads on all fittings and finger tighten to avoid stripping and cross-threading. ^ Tighten: Valve end fittings to 16.9 Nm (12.6 ft. lbs.). - Cylinder end fittings to 27 Nm (20 ft. lbs.). Rack Bearing Preload (on Vehicle Adjustment) 1. Make adjustment with front wheels raised and steering wheel centered. Be sure to check returnability of the steering wheel to center after adjustment. 2. Loosen adjuster plug lock nut (15) and turn adjuster plug clockwise until it bottoms in gear assembly (30), then back off 50° to 70° (approximately one flat). 3. Lock nut (15) to adjuster plug. ^ Tighten lock nut (15) to 68 Nm (50 ft. lbs.) while holding adjuster plug stationary. Rack, Pinion Boot & Breather Tube Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8615 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8616 ^ Tool Required: J 22610 Service Boot Clamp Installer - Or Equivalent REMOVE OR DISCONNECT 1. Do all steps of OUTER TIE ROD under "REMOVE OR DISCONNECT." 2. Hex jam nut (7) from inner tie rod assembly (12). 3. Tie rod end clamp (8). 4. Boot clamp (11) with side cutters and discard. Important: Mark location of breather tube (35) on gear assembly (30) before removing tube (35) or rack and pinion boot (10). 5. Rack and pinion boot (10) and breather tube (35). INSTALL OR CONNECT 1. New boot clamp (11) onto rack and pinion boot (10). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8617 2. Apply grease to inner tie rod (12) and gear assembly (30) prior to boot installation. ^ Boot (10) onto inner tie rod assembly (12). 3. Breather tube (35) aligned with mark made during removal, molded nipple of boot (10) to tube (35). 4. Boot (10) onto gear assembly (30) until seated in gear assembly groove. Important: Boot (10) must not be twisted, puckered or out of shape in any way. If the boot is not shaped properly, adjust by hand before installing boot clamp (11). 5. Boot clamp (11) on boot (10) with tool J 22610 and crimp as shown. 6. Tie rod end clamp (8) with pliers on boot (10). 7. Hex jam nut (7) to inner tie rod assembly (12). 8. Do all steps of OUTER TIE ROD under "INSTALL OR CONNECT." Rod/Rack and Cylinder Tube Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8618 Fig. 24 Exploded View Of Power Rack & Pinion Assembly 1. Remove dust cover from housing, Fig. 24. 2. While holding stub shaft, remove locknut from pinion. 3. With gear centered, mark location of stub shaft notch on housing to aid in proper installation of the pinion and valve assembly. 4. Using a suitable press, press on threaded end of pinion until it is possible to remove the pinion and valve assembly from the housing. 5. Remove stub shaft dust seal, stub shaft seal, stub shaft bearing annulus assembly, then the pinion and valve assembly with spool shaft retaining ring and valve body rings attached. 6. Using wrench, tool No. J 36343, or equivalent, remove cylinder tube assembly from housing. Mark location of fittings on housing before removal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8619 7. Remove piston rod guide rack from housing and disassemble as follows: a. Remove hex nut from rod and rack assembly. b. Remove rack piston with O-ring seal, piston ring and piston rod guide assembly. c. Remove O-ring seal and piston rod seal from piston rod guide. 8. Remove retaining ring from housing. 9. Remove pinion bearing assembly from housing. 10. Remove pinion shaft seal and upper pinion bushing from housing. 11. Coat all seals with power steering fluid. 12. Install upper pinion bushing into valve bore in housing. 13. Using seal installer tool No. J 29822, or equivalent, seat pinion shaft seal into housing. 14. Using suitable press, install pinion bearing assembly into housing. 15. Install retaining ring in groove in housing, positioning properly. 16. Assemble piston rod seal and O-ring seal to piston rod guide. 17. Assemble O-ring seal and piston ring to rack piston. 18. Slide seal back-up washer, piston rod guide assembly and rack piston onto rod and rack assembly. 19. Install hex nut on rod and rack assembly. Torque to 30 ft. lbs. 20. Slide piston rod guide assembly into housing. 21. Apply one small drop of Loctite 242, or equivalent, in three equally spaced locations around threaded portion of housing. Be sure to use sealant sparingly to ensure ease of removal of cylinder tube assembly if future repairs are necessary. 22. Slide cylinder tube assembly over rack piston ring to housing, then, using torque wrench, or equivalent, torque to 82 ft. lbs. Be sure to align fittings on cylinder tube with mark on housing before tightening to ensure cylinder line installation. 23. Assemble insert and rack guide assembly to rod and rack assembly in housing. 24. Center rack guide assembly in housing window opening. 25. Using protector tool No. J 33057, or equivalent, install pinion and valve assembly, together with new valve body rings, and spool shaft retaining ring into housing. When pinion and valve assembly is fully seated in housing, notch in stub shaft and mark on housing line up and insert and rack guide assembly is centered in window housing. 26. While holding stub shaft, torque locknut to 26 ft. lbs. 27. Install dust cover on housing. 28. Install stub shaft bearing annulus assembly onto stub shaft and slide into housing. 29. Place seal protector tool No. J 29810, or equivalent, onto stub shaft, then slide stub shaft seal and stub shaft dust seal over protector and into housing. 30. Install retaining ring into groove in housing. 31. Coat rack bearing, with O-ring seal attached, adjuster spring and the adjuster plug with lithium base grease and install in housing. 32. With rack centered in window in housing, turn adjuster plug clockwise until it bottoms in housing, then back off 50-70 °. Check pinion preload torque, which should not exceed 16 inch lbs. 32. Install locknut on adjuster plug and torque to 50 ft. lbs. while holding adjuster plug stationary. Upper Pinion Bushing and Pinion Shaft Seal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Seal Replacement Recommendations > Page 8620 Fig. 36 Pinion Shaft Seal & Bushing Removal 1. Remove upper pinion bushing and seal with a forceful punch, then install new bushing, Fig. 36. 2. Using pinion seal installer, tool No. J 29822, or equivalent, seat new seal in housing with seal tip facing up. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 8621 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column Steering Shaft: Customer Interest Steering - Clunk Felt/Noise Heard From Steering Column Bulletin No.: 07-02-32-006 Date: August 06, 2007 TECHNICAL Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate Intermediate Shaft [I-Shaft]) Models: 1997-2005 Chevrolet Cavalier 1997-2005 Pontiac Sunfire Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. Cause This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise. Diagnostic Tip This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Engineering investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigation shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease may temporarily eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: Locate a large area (parking lot) where the vehicle can be turned in a tight circle. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue the correction. Correction Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8630 Fully extend the intermediate shaft by pulling the two shafts apart. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8631 Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in. Make sure the intermediate shaft is being pressed over the ears of the solid shaft. Use a hard surface to ease the collapse of the intermediate shaft. It is best to use a pumping action when collapsing the shaft. Collapse the shaft as far as possible. Remove the rubber stopper plug from the yoke end of the shaft. Slowly extend the intermediate shaft apart. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8632 Before installing the intermediate shaft in the vehicle, make sure to stoke and extend the intermediate shaft at least 15 times to completely lubricate the internal surface of the slip joint. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in Service Information (SI). Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column Steering Shaft: All Technical Service Bulletins Steering - Clunk Felt/Noise Heard From Steering Column Bulletin No.: 07-02-32-006 Date: August 06, 2007 TECHNICAL Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate Intermediate Shaft [I-Shaft]) Models: 1997-2005 Chevrolet Cavalier 1997-2005 Pontiac Sunfire Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. Cause This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise. Diagnostic Tip This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Engineering investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigation shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease may temporarily eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: Locate a large area (parking lot) where the vehicle can be turned in a tight circle. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue the correction. Correction Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8638 Fully extend the intermediate shaft by pulling the two shafts apart. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8639 Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in. Make sure the intermediate shaft is being pressed over the ears of the solid shaft. Use a hard surface to ease the collapse of the intermediate shaft. It is best to use a pumping action when collapsing the shaft. Collapse the shaft as far as possible. Remove the rubber stopper plug from the yoke end of the shaft. Slowly extend the intermediate shaft apart. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 8640 Before installing the intermediate shaft in the vehicle, make sure to stoke and extend the intermediate shaft at least 15 times to completely lubricate the internal surface of the slip joint. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in Service Information (SI). Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Steering Wheel: Service and Repair Steering Wheel Precautions The procedures must be followed in the order listed to temporarily disable the Supplemental Inflatable Restraint (SIR) System and prevent false Diagnostic Trouble Codes from setting. Failure to follow procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. The DERM can maintain sufficient voltage to cause a deployment for 10 minutes after the ignition switch is turned "OFF" or the battery is disconnected. Many of the service procedures require disconnection of the SIR fuse and inflator module circuits from the deployment loop to avoid an accidental deployment. Disabling SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. -Turn the ignition switch to "LOCK". 1. AIR BAG fuse #1. 2. Left sound insulator. 3. Connector position assurance (CPA) and yellow two-way SIR harness connector at base of steering column. Enabling the SIR System INSTALL OR CONNECT 1. Turn ignition switch to "OFF". 2. Route wire around post on back of module and under tab. 3. Yellow two-way Supplemental Inflatable Restraint (SIR) connector and connector position assurance (CPA) at base of steering column. 4. Left sound insulator. 5. AIR BAG fuse #1. 6. Turn ignition to "RUN" and make sure the "INFLATABLE RESTRAINT" indicator lamp flashes 7 to 9 times and then goes out. Handling Precautions - SIR LIVE (UNDEPLOYED) INFLATOR MODULE Special care is necessary when handling and storing a live (undeployed) Inflator Module. The rapid gas generation produced during deployment of the air bag could cause the Inflator Module, or an object in front of the Inflator Module, to be thrown through the air in the unlikely event of an accidental deployment. CAUTION: When carrying a live inflator module, make sure the bag opening is pointed away from you. Never carry the inflator module by the wires or connector on the underside of the module. In case of an accidental deployment, the bag will then deploy with minimal chance of Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel > Page 8645 injury. When placing a live inflator module on bench or other surface, always face the bag and trim cover up, away from the surface. Never rest a steering column assembly on the steering wheel with the inflator module face down and column vertical. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result. DEPLOYED INFLATOR MODULES After an Inflator Module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of corn starch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye is produced as a by-product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. As with many service procedures, you should wear gloves and safety glasses. INFLATOR MODULE SHIPPING PROCEDURES FOR LIVE (UNDEPLOYED) INFLATOR MODULES Service personnel should refer to the latest Service Bulletins for proper Supplemental Inflatable Restraint (SIR) inflator module shipping procedures. INFLATOR MODULE SCRAPPING PROCEDURE During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) inflator module. This information covers proper procedures for disposing of a live inflator module. Before a live inflator module can be disposed of, it must be deployed. Live inflator modules must not be disposes of through normal refuse channels. CAUTION: Failure to follow proper Supplemental Inflatable Restraint (SIR) inflator module disposal procedures can result in air bag deployment which may cause personal injury. Undeployed inflator modules must not be disposed of through normal refuel channels. The undeployed inflator module contains substances that can cause severe illness or personal injury if the sealed container is damaged during disposal. Disposal in any manner inconsistent with proper procedures may be a violation of federal, state, and/or local laws. If a vehicle is the subject of a Product Liability Report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), DO NOT DEPLOY the inflator module and SO NOT ALTER the SIR system in any manner. Refer to the applicable service bulletin on SIR shipping procedures for details on handling SIR systems involved with GM-1241. If a vehicle is the subject of a campaign affecting inflator modules, DO NOT DEPLOY the inflator module. Follow instruction in the Campaign Service Bulletin for proper disposition of the inflator module. If an inflator module is replaced under warranty, DO NOT DEPLOY the air bag. The inflator module may need to be returned, undeployed, to Inland Fisher Guide. Refer to procedures shown in the appropriate service bulletin regarding SIR shipping procedures. In situations which require deployment of alive (undeployed) driver inflator module, deployment may be accomplished inside or outside the vehicle. The method employed depends upon the final disposition of the particular vehicle, as noted in "Deployment Outside Vehicle" and "Deployment Inside Vehicle." WIRING REPAIR SUPPLEMENTAL INFLATABLE RESTRAINT If the wiring pigtail (wires attached directly to the component, not by a connector) on either the Inflator Module or the SIR Coil Assembly is damaged, the entire component must be replaced. Absolutely no wire, connector, or terminal repairs are to be attempted on either the Inflator Module or the SIR Coil Assembly. Inflator Module - Supplemental Inflatable Restraint (SIR) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel > Page 8646 REMOVE OR DISCONNECT 1. Disable the Supplemental Inflatable Restraint (SIR) system. 2. Two screws from the back of the steering wheel using a Hex Head driver (or equivalent). 3. Connector position assurance (CPA) and electrical connection from rear of inflator module. 4. Inflator module. INSTALL OR CONNECT 1. CPA to rear of inflator module. 2. Inflator module to steering wheel and four screws through back of steering wheel. ^ Tighten screws to 10 Nm (89 inch lbs.). 3. Enable the SIR system. Steering Wheel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel > Page 8647 ^ Tool Required: J 1859-A Steering Wheel Puller - Or Equivalent REMOVE OR DISCONNECT 1. Disable the Supplemental Inflatable Restraint (SIR) system. 2. Inflator module and horn connection. 3. Nut. 4. Steering wheel using J 1859-A. INSTALL OR CONNECT 1. Align mark on steering wheel with mark on shaft, then install steering wheel. 2. Nut. ^ Tighten steering wheel nut to 41 Nm (30 ft. lbs.). 3. Horn connection and Inflator module. 4. Enable the SIR system. Coil Assembly- Supplemental Inflatable Restraint (SIR) REMOVE OR DISCONNECT Important: Disable the Supplemental Inflatable Restraint (SIR) system. 1. Steering wheel assembly. 2. Coil assembly retaining clip. 3. Coil assembly off shaft end letting coil hang freely. 4. Wave washer. 5. Spacer shaft lock (standard column only). 6. Shaft lock retaining ring using J 23563-C to compress lock. 7. Pry off retaining ring. 8. Shaft lock. 9. Turn signal canceling cam assembly. 10. Upper bearing spring. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel > Page 8648 11. Turn signal to right turn position (up). 12. Multifunction lever. 13. Hazard knob assembly. 14. Screw and signal switch arm. ^ Let switch arm hang freely (tilt option equipped with cruise only). 15. Screws, turn signal switch. ^ Let turn signal switch hang freely. 16. Remove coil assembly connector shroud. 17. Steering column support bracket bolts. 18. Upper steering column bolts. 19. Wiring protector. 20. Connect a length of mechanic's wire to coil assembly terminal connector to aid in reassembly. 21. Gently pull wire harness through steering column housing shroud, steering column housing and lock assembly cover. 22. Remove mechanic's wire. INSTALL OR CONNECT NOTICE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. 1. Connect mechanic's wire to centering coil assembly connector. 2. Gently pull connector through steering column housing shroud, steering column housing and lock assembly. 3. Remove mechanic's wire. 4. Install wiring protector. 5. Install connector shroud. 6. Connector centering coil assembly terminal connector. 7. Steering column lower support bracket to steering column. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 8. Steering column upper support bolts. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 9. Turn signal switch assembly. ^ Tighten bolts to 3.4 Nm (30 inch lbs.). 10. Signal switch arm (tilt steering column only). ^ Tighten bolts to 2.3 Nm (20 inch lbs.). 11. Hazard knob assembly. 12. Multifunction lever. 13. Turn signal canceling cam assembly. ^ Lubricate with grease, synthetic (service kit). 14. Shaft lock. ^ Inspect shaft lock retaining ring for damage or deformation. Replace with new retaining ring. 15. Shaft lock retaining ring. Line up to block tooth on shaft using J 23653-C to compress shaft lock. ^ Shaft lock retaining ring must be firmly seated in groove on shaft. 16. Spacer shaft lock (standard column only). 17. Ensure coil assembly is centered. Important: Assemble pre-centered coil assembly to steering column. Remove centering tab and dispose. Important: Coil assembly will become un-centered if: a. Steering column is separated form steering gear and is allowed to rotate. b. Centering spring is pushed down, letting hub rotate while coil is removed from steering column. In the event this occurs, refer to "Centering Coil Assembly." 18. Coil assembly using horn tower on canceling cam assembly inner ring and projections on outer ring for alignment. 19. Coil assembly retaining ring. ^ Ring must be firmly in groove on shaft. Important: Gently pull lower coil assembly wire to remove any wire kinks that may be inside column assembly. It is absolutely critical that you make sure there are no kinks or bends in the SIR coil assembly wire. If a kink or bend is present, interference may occur with the shaft lock mechanism. Then turning of the steering wheel may cut or damage wire. 20. Steering wheel assembly. 21. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel > Page 8649 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel > Page 8650 Steering Wheel: Service and Repair Steering Wheel Replacement Supplemental Inflatable Restraint (SIR) The supplemental Inflatable Restraint (SIR) system helps supplement the protection offered by the driver's seat belt by deploying an air bag from the center of the steering wheel during certain frontal crashes. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30° off the centerline of the vehicle. The steering column is collapsible and should be inspected after an accident whether or not deployment has occurred. Lubrication Apply a thin coat of lithium grease to all friction parts when assembling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Various Revised Tightening Specifications Tie Rod End: Technical Service Bulletins Steering - Various Revised Tightening Specifications CHEVROLET 73-32-03A Issued: 05/01/97 SMU - SECTIONS 3B/3C/4D REVISION: 04/11/97 THIS BULLETIN IS BEING REVISED TO UPDATE THE DRIVE AXLE NUT TIGHTENING SPECIFICATIONS FOR THE N CAR. PLEASE DISCARD CORPORATE BULLETIN NUMBER 73-32-03 (SECTION 3 - STEERING/SUSPENSION). SUBJECT: SERVICE MANUAL UPDATE - SECTIONS 3B/3C/4D - REVISED TIGHTENING SPECIFICATIONS MODELS: 1997 CHEVROLET CAVALIER, MALIBU 1997 OLDSMOBILE CUTLASS 1997 PONTIAC SUNFIRE THIS BULLETIN IS BEING ISSUED TO REVISE THE TIGHTENING SPECIFICATIONS IN SECTIONS 3B, 3C AND 4D OF THE SERVICE MANUAL AS FOLLOWS: J CAR SECTIONS 3B-8, 3B-9, 3C-5 AND 3C-13: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 90 DEGREE ROTATION. N CAR SECTIONS 3C-6 AND 3C-16: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 180 DEGREE ROTATION. SECTION 3B-12: THE CORRECT TIGHTENING SPECIFICATIONS ARE AS FOLLOWS: - STEERING COLUMN LOWER PINCH BOLT 22 N.M (16 LB FT) - STEERING COLUMN UPPER PINCH BOLT 22 N.M (16 LB FT) SECTIONS 3C-16, 4D-4 AND 4D-5: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - FRONT DRIVE AXLE NUT 385 N.M (284 LB FT) +/- 5 N.M (44 LB IN). REPLACE THE DRIVE AXLE NUT WITH A NEW ONE AFTER EVERY REMOVAL. NEVER RE-USE THE DRIVE AXLE NUT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball joints must be replaced if any looseness is detected in the joint or the ball joint seal is cut. To inspect the ball joints, raise the front of the vehicle allowing the front suspension to hang free. Grasp the tire at the top and bottom and move the top of tire with an in-and-out motion. Observe ball joint for any horizontal movement of the steering knuckle relative to the front lower control arm. If the ball stud is disconnected from the steering knuckle and any looseness is detected, or if the ball stud can be twisted in its socket using finger pressure, replace the ball joint. Ball stud tightness in the steering knuckle boss should also be checked when inspecting the ball joint. This may be done by shaking the wheel and feeling for movement of the stud end or castellated nut at the knuckle boss. Checking the castellated nut fastener tightening specification is an alternative method of inspecting for wear A loose nut can indicate a bent stud or an "opened-up" hole in the knuckle boss. Worn or damaged ball joints and knuckles must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8660 Ball Joint: Testing and Inspection Ball joints must be replaced if any looseness is detected in the joint or the ball joint seal is cut. To inspect the ball joints, raise the front of the vehicle allowing the front suspension to hang free. Grasp the tire at the top and bottom and move the top of tire with an in-and-out motion. Observe ball joint for any horizontal movement of the steering knuckle relative to the front lower control arm. If the ball stud is disconnected from the steering knuckle and any looseness is detected, or if the ball stud can be twisted in its socket using finger pressure, replace the ball joint. Ball stud tightness in the steering knuckle boss should also be checked when inspecting the ball joint. This may be done by shaking the wheel and feeling for movement of the stud end or castellated nut at the knuckle boss. Checking the castellated nut fastener tightening specification is an alternative method of inspecting for wear A loose nut can indicate a bent stud or an "opened-up" hole in the knuckle boss. Worn or damaged ball joints and knuckles must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8661 Ball Joint: Service and Repair ^ Tool Required: J 38892 Ball Joint Separator - Or Equivalent REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. If suspension contact hoist is used: - Place jack stands under crossmember. - Lower vehicle slightly so weight of vehicle rests on the crossmember and not the control arms. 3. Tire and wheel assembly. NOTICE: Care must be exercised to prevent the axle shaft joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of internal components and possible joint failure. Failure to observe this can result in interior joint or boot damage and possible joint failure. 4. Nut and cotter pin from ball joint. 5. Separate ball joint from steering knuckle using J 38892. NOTICE: Use only the recommended tool for separating the ball joint from knuckle. Failure to use the recommended tool may cause damage to the ball joint and seal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8662 6. Drill out three rivets retaining ball joint to lower control arm. Use a 3 mm (1/8 inch) drill bit to make a pilot hole through the rivets. Finish drilling rivets with 13 mm (1/2 inch) drill bit. Important: Do not, damage drive axle boot when drilling out ball joint rivets. 7. Nut attaching link to stabilizer shaft. 8. Ball joint from steering knuckle and control arm. INSTALL OR CONNECT 1. Ball joint in control arm. 2. Three (3) ball joint bolts and nuts as shown on instruction sheet in ball joint kit and tighten ball joint bolts to specifications. 3. Ball joint stud through steering knuckle. 4. Ball joint nut. ^ Tighten ball joint to steering knuckle nut to 55 Nm (41 ft. lbs.) minimum, 65 Nm (50 ft. lbs.) maximum, to install cotter pin. ^ Do not loosen nut any time during installation. 5. Cotter pin. 6. Nut attaching stabilizer link to stabilizer shaft. ^ Tighten nut to 17 Nm (13 ft. lbs.). 7. Tire and wheel assembly. 8. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension Control Arm Bushing: Service and Repair Front Suspension ^ Tools Required: J 29792 Lower Control Arm Front Bushing Service Set - J 41211 Lower Control Arm Rear Vertical Bushing Service Set - Or Equivalents REMOVE OR DISCONNECT 1. Lower control arm. ^ Install bushing removal tools. ^ Coat threads of tool J 29792 with an extreme pressure lubricant. 2. Lower control arm bushings. INSTALL OR CONNECT 1. Install bushing installation tools. 2. Lower control arm bushings. ^ To ease installation, coat outer casing of new bushing with a lubricant. 3. Lower control arm. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 8668 Control Arm Bushing: Service and Repair Rear Suspension ^ Tools Required: J 21474- 18 3/8in Nut - J 2147119 3/8in Bolt - J 29376-A Rear Control Arm Bushing Service Set - Or Equivalents REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Support vehicle with jackstands under axle. 3. Wheel and tire assemblies. 4. If removing right bushings, disconnect brake lines from body. If left bushings are being removed, disconnect brake line bracket from body, and parking brake cable from hook guide on the body. 5. Nut, bolt, and washer from the control arm and underbody attachment, and rotate control arm downward. (Remove and install one control arm bushing at a time.) NOTICE: Do not suspend rear axle by brake hoses. Damage to hoses could result. 6. Bushing as follows: A. Install J 29376-1 on control arm over bushing and tighten attaching nuts until tool is securely in place. B. Install J 21474-19 bolt through plate J 29376-7 and install into J 29376-1 receiver. Place J29376-6A remover into position on bushing and install nut J 21474- 18 onto J 21474-19 bolt. C. Bushing from control arm by turning bolt. INSTALL OR CONNECT 1. Bushing as follows: A. J 29376-1 receiver on control arm. B. J 21474-19 bolt through plate J 29376-7 and install into J 29376-1 receiver. C. Bushing on bolt and position into housing. Align bushing installer arrow with arrow on receiver for proper indexing of bushing. (A high pressure lubricant such as J 234-14 A or equivalent may be necessary to aid in assembly.) D. Nut J 21474-18 onto bolt J 21474-19. E. Press bushing into control arm by turning bolt. When bushing is in proper position, the end flange will be flush against the face of the control arm. 2. Align control arm and underbody attachment, and loosely install bolt, washer, and nut. Important: Washer and nut must be installed on outboard side. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 8669 3. Left and right brake pipe brackets and attaching screws. ^ Tighten screws to 11 Nm (97 inch lbs.). 4. Wheel and tire assemblies. 5. Remove jackstands and lower vehicle to curb height. ^ Tighten control arm nuts 60 Nm (44 ft. lbs.) plus 120° rotation using J 36660. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Suspension (Front) - Torque Specification Update Cross-Member: Technical Service Bulletins Suspension (Front) - Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 02-03-08-006 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Front Suspension Fastener Tightening Specifications Models: 1997-2002 Chevrolet Cavalier 1997-2002 Pontiac Sunfire This bulletin is being issued to revise the fastener tightening specifications in the Lower Control Arm Replacement Procedure and the Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following tightening specification has been revised: Control Arm to Crossmember Bolts (Front Bushing) - 100 N.m plus 90 degrees rotation (74 lb ft). DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Page 8674 Cross-Member: Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Page 8675 ^ Tool Required: J 38892 Ball Joint Separator - Or Equivalent REMOVE OR DISCONNECT 1. Raise vehicle. 2. If suspension contact hoist is used: ^ Place jack stands under uni-body frame near crossmember. ^ Lower vehicle slightly so weight of vehicle rests on the under uni-body frame and not on the control arms or crossmember. 3. Tire and wheel assembly. 4. Right and Left wiring baronesses from crossmember. 5. Ball joint from knuckle using J 38892. NOTICE: Use only the recommended tool for separating the ball joint from knuckle. Failure to use the recommended tool may cause damage to the ball joint and seal. 6. Engine strut to crossmember. 7. Crossmember support braces. 8. Front exhaust pipe, (support catalytic converter). 9. Power steering gear bolts, (support power steering gear). 10. Brake lines from retainers on crossmember. 11. Splash shield from crossmember. 12. Stabilizer bar from crossmember. 13. Crossmember. 14. Control arms from crossmember. INSTALL OR CONNECT 1. Control arms to crossmember and snug bolts only. 2. Crossmember and snug all bolts lightly. 3. Tighten bolts in sequence shown below. ^ Tighten: Crossmember Support Left Rear Outboard Bolt 110 Nm (71 ft. lbs.) plus 90° rotation. - Crossmember Support Right Rear Outboard Bolt 110 Nm (71 ft. lbs.) plus 90° rotation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Page 8676 - Crossmember Support Upper Front Bolts 110 Nm (71 ft. lbs.) plus 90° rotation. - Crossmember Support Rear Inboard Bolts 110 Nm (71 ft. lbs.) plus 90° rotation. 4. Nut attaching ball joint to steering knuckle. Tighten to specifications. ^ Tighten ball joint to steering knuckle nut to 55 Nm (41 ft. lbs.) minimum, 65 Nm (50 ft. lbs.) maximum. Important: Do not loosen nut any time during installation. 5. Power steering gear bolts, hand start bolts and nuts. Tighten left side bolt and nuts to specification first, then tighten right side bolt and nut to specification. 6. Front exhaust pipe. 7. Crossmember support braces. ^ Tighten crossmember braces to core support bolts 72 Nm (53 ft. lbs.). 8. Engine strut to crossmember. 9. Stabilizer bar to crossmember. ^ Tighten stabilizer shaft to support assembly bolts to 66 Nm (49 ft. lbs.). 10. Splash shield to crossmember. 11. Brake lines to retainers to crossmember. 12. Right and Left wiring harenesses to crossmember. 13. Slightly raise vehicle. 14. Remove jack stands from under crossmember. 15. Tire and wheel assembly. 16. With vehicle at curb height, tighten control arm attaching bolts to specifications. ^ Tighten: Control Arm to Crossmember Bolts (Front Bushing) 120 Nm (89 ft. lbs.) plus 180° rotation - Control Arm to Crossmember Bolts (Rear Vertical Bushing) 170 Nm (125 ft. lbs.) 17. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Steering - Various Revised Tightening Specifications Front Steering Knuckle: Technical Service Bulletins Steering - Various Revised Tightening Specifications CHEVROLET 73-32-03A Issued: 05/01/97 SMU - SECTIONS 3B/3C/4D REVISION: 04/11/97 THIS BULLETIN IS BEING REVISED TO UPDATE THE DRIVE AXLE NUT TIGHTENING SPECIFICATIONS FOR THE N CAR. PLEASE DISCARD CORPORATE BULLETIN NUMBER 73-32-03 (SECTION 3 - STEERING/SUSPENSION). SUBJECT: SERVICE MANUAL UPDATE - SECTIONS 3B/3C/4D - REVISED TIGHTENING SPECIFICATIONS MODELS: 1997 CHEVROLET CAVALIER, MALIBU 1997 OLDSMOBILE CUTLASS 1997 PONTIAC SUNFIRE THIS BULLETIN IS BEING ISSUED TO REVISE THE TIGHTENING SPECIFICATIONS IN SECTIONS 3B, 3C AND 4D OF THE SERVICE MANUAL AS FOLLOWS: J CAR SECTIONS 3B-8, 3B-9, 3C-5 AND 3C-13: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 90 DEGREE ROTATION. N CAR SECTIONS 3C-6 AND 3C-16: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 180 DEGREE ROTATION. SECTION 3B-12: THE CORRECT TIGHTENING SPECIFICATIONS ARE AS FOLLOWS: - STEERING COLUMN LOWER PINCH BOLT 22 N.M (16 LB FT) - STEERING COLUMN UPPER PINCH BOLT 22 N.M (16 LB FT) SECTIONS 3C-16, 4D-4 AND 4D-5: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - FRONT DRIVE AXLE NUT 385 N.M (284 LB FT) +/- 5 N.M (44 LB IN). REPLACE THE DRIVE AXLE NUT WITH A NEW ONE AFTER EVERY REMOVAL. NEVER RE-USE THE DRIVE AXLE NUT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service Front Steering Knuckle: Service and Repair On-Vehicle Service Ball Joint and Knuckle Inspection Ball joints must be replaced if any looseness is detected in the joint or the ball joint seal is cut. To inspect the ball joints, raise the front of the vehicle allowing the front suspension to hang free. Grasp the tire at the top and bottom and move the top of tire with an in-and-out motion. Observe ball joint for any horizontal movement of the steering knuckle relative to the front lower control arm. If the ball stud is disconnected from the steering knuckle and any looseness is detected, or if the ball stud can be twisted in its socket using finger pressure, replace the ball joint. Ball stud tightness in the steering knuckle boss should also be checked when inspecting the ball joint. This may be done by shaking the wheel and feeling for movement of the stud end or castellated nut at the knuckle boss. Checking the castellated nut fastener tightening specification is an alternative method of inspecting for wear A loose nut can indicate a bent stud or an "opened-up" hole in the knuckle boss. Worn or damaged ball joints and knuckles must be replaced. Steering Knuckle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service > Page 8683 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service > Page 8684 ^ Tools Required: J 38892 Ball Joint Separator - J 28733-A Front Hub Spindle Remover - Or Equivalents REMOVE OR DISCONNECT 1. Hub and bearing assembly. 2. Bolts attaching steering knuckle to strut. INSTALL OR CONNECT 1. Steering knuckle into strut and install steering knuckle-to-strut assembly bolts. ^ Tighten steering knuckle-to-strut assembly nuts to 180 Nm (133 ft. lbs.). 2. Hub and bearing assembly onto knuckle and install hub and bearing assembly bolts. 3. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > On-Vehicle Service > Page 8685 Front Steering Knuckle: Service and Repair Strut and Knuckle Scribing 1. Using a sharp tool, scribe the knuckle along the lower outboard strut radius as shown. 2. Scribe the strut flange on the inboard side along the curve of the knuckle, as shown. 3. Make a scribe mark across the strut/knuckle interface as shown. 4. On reassembly, carefully match the marks to the components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Page 8690 REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. Allow front suspension to hang free. 2. Front tire and wheel assemblies. 3. Clamps attaching stabilizer shaft to crossmember assemblies. 4. Stabilizer shaft bushings. INSTALL OR CONNECT 1. Stabilizer shaft with insulators into vehicle (hand tighten). 2. Clamps attaching stabilizer shaft to crossmember assemblies (hand tighten). 3. Crossmember assemblies into position and install bolts (hand tighten). 4. Tighten crossmember bolts left rear outboard first right rear outboard second, front upper third, rear inboard last to specifications. ^ Tighten: Left rear outboard bolt, first to 110 Nm (71 ft. lbs.) plus 90° rotation. - Right rear outboard bolt, second to 110 Nm (71 ft. lbs.) plus 90° rotation. - Front upper bolts third to 110 Nm (71 ft. lbs.) plus 90° rotation. - Rear inboard bolts last to 110 Nm (71 ft. lbs.) plus 90° rotation. 5. Tighten clamp bolts to crossmember to specifications. ^ Tighten stabilizer shaft bushing clamp to support assembly bolts to 66 Nm (49 ft. lbs.). 6. Tighten stabilizer links to control arm. ^ Tighten stabilizer shaft links to control arm nuts to 17 Nm (13 ft. lbs.). 7. Front wheel and tire assemblies. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 733403 > Apr > 97 > Suspension - Rear Shock Noise In Trunk Area Suspension Strut / Shock Absorber: Customer Interest Suspension - Rear Shock Noise In Trunk Area File In Section: 3 - Steering/Suspension Bulletin No.: 73-34-03 Date: April, 1997 Subject: "Loose Lumber" Rear Shock Noise in Trunk Area (Inspect/Replace Rear Upper Strut Mount) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire Condition Some owners may comment on a rear shock noise which sounds like loose logs or lumber in the trunk area. This noise or rattle is present in cold ambient temperatures and may be more noticeable with uneven or snow packed road surfaces at slow speeds, usually 5 - 20 mph (8 - 32 km/h). Cause Rear shock damping response may be transmitted through the body structure and heard as a loose lumber noise. Correction A new softer durometer upper shock mount will go into production approximately March of 1997. Important: It is still necessary to diagnose the condition as follows. 1. Inspect and re-torque rear upper shock mounts, lower shock mounts, and bracket to axle. 2. Remove the upper strut mount to body bolts and nut. Refer to Section 3D of the Service Manual. 3. Inspect for the presence of underbody coating between the strut mount and the body. Remove any material so that the upper mount mates to the painted surface. 4. If the above is OK, install revised upper shock mount, P/N 22178213, and recheck. Parts Information P/N Description 22178213 Upper Shock Mount Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time E5057 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 8704 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 72-05-12 > Jan > 98 > Suspension - Shock Absorber/Strut Replacement Guidlines Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Replacement Guidlines File In Section: Warranty Administration Bulletin No.: 72-05-12 Date: January, 1998 WARRANTY ADMINISTRATION Subject: Replacement of Shock Absorbers and Struts Labor Operations E3800, E3801, E3807, E5800, E5801, E5807, E3850, E3851, E3857, E5750, E5751, and E5757 Models: All Past, Present, and Future Passenger Cars & Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with enhanced service policies for the above listed subject labor operations. Service Management should make certain that all dealership personnel responsible for replacement of suspension components are familiar with GM Service Manual procedures. Effective with repair orders dated on or after January 15, 1998 the following must also be followed: - Shock absorber/strut assemblies are fluid filled components and will normally exhibit seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorber/strut assemblies are not to be replaced under warranty or seepage. - Defective shock absorber/strut assemblies will have a visible oil path or drip coming from the component. A visible oil path or drip coming from the shock absorber/strut assembly should be replaced as a defective component. - Only defective shock absorber/strut assemblies should be replaced. DO NOT replace pairs unless both are defective, unless otherwise instructed in the Service Manual and/or Service Bulletin. - Service Management approval is required on the repair order for replacement of struts or shocks in pairs. This approval includes noting the reason for replacement. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 733403 > Apr > 97 > Suspension - Rear Shock Noise In Trunk Area Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rear Shock Noise In Trunk Area File In Section: 3 - Steering/Suspension Bulletin No.: 73-34-03 Date: April, 1997 Subject: "Loose Lumber" Rear Shock Noise in Trunk Area (Inspect/Replace Rear Upper Strut Mount) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire Condition Some owners may comment on a rear shock noise which sounds like loose logs or lumber in the trunk area. This noise or rattle is present in cold ambient temperatures and may be more noticeable with uneven or snow packed road surfaces at slow speeds, usually 5 - 20 mph (8 - 32 km/h). Cause Rear shock damping response may be transmitted through the body structure and heard as a loose lumber noise. Correction A new softer durometer upper shock mount will go into production approximately March of 1997. Important: It is still necessary to diagnose the condition as follows. 1. Inspect and re-torque rear upper shock mounts, lower shock mounts, and bracket to axle. 2. Remove the upper strut mount to body bolts and nut. Refer to Section 3D of the Service Manual. 3. Inspect for the presence of underbody coating between the strut mount and the body. Remove any material so that the upper mount mates to the painted surface. 4. If the above is OK, install revised upper shock mount, P/N 22178213, and recheck. Parts Information P/N Description 22178213 Upper Shock Mount Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time E5057 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 8718 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 72-05-12 > Jan > 98 > Suspension - Shock Absorber/Strut Replacement Guidlines Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Replacement Guidlines File In Section: Warranty Administration Bulletin No.: 72-05-12 Date: January, 1998 WARRANTY ADMINISTRATION Subject: Replacement of Shock Absorbers and Struts Labor Operations E3800, E3801, E3807, E5800, E5801, E5807, E3850, E3851, E3857, E5750, E5751, and E5757 Models: All Past, Present, and Future Passenger Cars & Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with enhanced service policies for the above listed subject labor operations. Service Management should make certain that all dealership personnel responsible for replacement of suspension components are familiar with GM Service Manual procedures. Effective with repair orders dated on or after January 15, 1998 the following must also be followed: - Shock absorber/strut assemblies are fluid filled components and will normally exhibit seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorber/strut assemblies are not to be replaced under warranty or seepage. - Defective shock absorber/strut assemblies will have a visible oil path or drip coming from the component. A visible oil path or drip coming from the shock absorber/strut assembly should be replaced as a defective component. - Only defective shock absorber/strut assemblies should be replaced. DO NOT replace pairs unless both are defective, unless otherwise instructed in the Service Manual and/or Service Bulletin. - Service Management approval is required on the repair order for replacement of struts or shocks in pairs. This approval includes noting the reason for replacement. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > General Information Suspension Strut / Shock Absorber: Testing and Inspection General Information The strut dampener is basically a shock absorber. Strut dampeners are easier than shock absorbers to extend and retract by hand. The procedure includes both on-vehicle and off-vehicle checks to be done when evaluating the performance of strut dampeners and shock absorbers. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > General Information > Page 8725 Suspension Strut / Shock Absorber: Testing and Inspection On-Vehicle Checks WEAK CONDITION For struts, follow Steps 1 through 4. 1. Check and adjust tire pressures to the pressures shown on the Tire Placard. 2. Note the load conditions under which the vehicle is normally driven. 3. If practical, ride with the owner to be sure you understand the complaint before proceeding to next step. 4. Test each strut dampener/shock in turn by quickly pushing down, then lifting up (bouncing), the corner of the bumper nearest the strut dampener/shock being checked. Use the same amount of effort on each test and note the resistance on compression and rebound. Compare this with a similar vehicle having acceptable ride quality. Both strut dampeners/shocks should provide the same feeling of resistance. NOISY CONDITION For struts, follow Steps 1 through 4. 1. Check all mountings for proper tightening specification. A loose mounting will cause a noise. 2. If all mountings are intact, bounce the vehicle as in Step 4 (in "Weak Condition" above) to isolate the suspected unit. 3. If practical, ride with the owner to be sure you understand the complaint. 4. Other objectionable noises may be detected by jouncing the vehicle up and down. Any sound coming from the shock other than hissing is abnormal, therefore replace the shock. LEAKS 1. Fully extend the strut/shocks (wheels unsupported) to expose the seal cover area for inspection. 2. Look for signs of leaks in the seal cover area. 3. A slight trace of fluid is NOT cause for replacement; the seal permits some seepage to lubricate the piston rod. There is a built in fluid reserve to allow for seepage. 4. A leaking strut dampener/shock can easily be found because there will be fluid around the seal cover and an excessive amount of fluid on the strut dampener/shock. A leaking strut dampener/shock must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > General Information > Page 8726 Suspension Strut / Shock Absorber: Testing and Inspection Off-Vehicle Checks All strut dampeners and shock absorbers should be stroked before attempting an off-vehicle check. When stored horizontally, such as new units in stock, an air pocket will develop in the pressure chamber. An air pocket will also form if the vehicle has been stationary for a period of time. Do the following to remove air from the pressure chamber: ^ Extend in vertical position - top end-up. ^ Collapse in vertical position - top end down. ^ Do this again five more times to make sure air is purged from the pressure chamber. Proceed with the actual off-vehicle check as follows: 1. Clamp a vise on the bottom mount with the strut dampener or shock absorber upright in the vise top end up. Do not clamp on the reservoir tube or the mounting threads. 2. Pump strut dampener or shock absorber by hand at various rates of speed and note the resistance. 3. Rebound resistance normally is stronger than compression resistance by about 2 to 1. However, the resistance should be smooth and constant for each stroking rate. 4. Compare with a strut dampener or shock absorber known to be good. 5. It is normal to hear a hissing noise. The following symptoms are abnormal and are reason for replacement. A. A skip or lag at reversal near mid-stroke. B. A seize (except at either extreme end of travel). C. A noise (such as a grunt or squeal) after completing one full stroke in both directions. D. A clicking noise at fast reversal. E. Fluid leakage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service Suspension Strut / Shock Absorber: Service and Repair On-Vehicle Service Coil-Over Shock Absorber REMOVE OR DISCONNECT 1. Open rear compartment. 2. Coil-over shock absorber upper shock absorber attaching nut. Remove one coil-over shock at a time when both coil-over shocks are to be replaced. 3. Raise vehicle on hoist and support rear axle with adjustable jackstands. A. When lifting vehicle with body hoist, it will be necessary to support rear axle with adjustable jackstands. B. When lifting vehicle with suspension hoist, it will be necessary to support rear axle with adjustable jackstands. 4. Bolts from coil-over shock upper mount. 5. Coil-over shock mounting bolt. Remove coil-over shock. NOTICE: Do not remove both shock absorbers at one time as suspending rear axle at full length could result in damage to brake pipes and hoses. INSTALL OR CONNECT 1. Coil-over shock absorbers at lower attachment. Install bolt hand tight. 2. Bolts to coil-over shock upper mount. 3. Lower vehicle. 4. Coil-over shock upper mount attaching nut. 5. Tighten coil-over shock lower attachment bolt to specification. ^ Tighten: Coil-over shock absorber lower mounting bolts to 170 Nm (125 ft. lbs.). - Coil-over shock absorber upper mount bolts and nut 28 Nm (21 ft. lbs.). 6. Remove axle support and lower vehicle all the way then tighten shock absorber upper nut. Coil-Over Shock Absorber Lower Adapter Bracket Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8729 REMOVE OR DISCONNECT 1. Coil-over shock absorber lower nut. 2. Coil-over shock lower adapter bolt and nut. INSTALL OR CONNECT 1. Coil-over shock lower adapter and bolt. 2. Shock absorber lower nut. ^ Tighten coil-over shock absorber adapter nut 70 Nm (52 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8730 Suspension Strut / Shock Absorber: Service and Repair Unit Repair Shock Absorber ^ Tools Required: J 3289-20 Holding Fixture - J 34013-A Strut Compressor - J 41046-Coil Over Shock Adapters - Or Equivalents DISASSEMBLE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. 1. Mount Strut Compressor J 34013 in Holding Fixture J 3289-20. 2. Mount Coil-over shock into Strut Compressor. Notice that Strut Compressor has strut mounting holes drilled for specific car line. The adapter plate J 41046 must be installed first. 3. Compress Coil-over shock approximately 1/2 its height after initial contact with top cap. NEVER BOTTOM SPRING OR DAMPENER ROD. 4. Remove the nut from the Coil-over shock dampener shaft. Remove components. ASSEMBLE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. 1. Install bearing cap into Strut Compressor if previously removed. 2. Mount Coil-over shock into Strut Compressor using bottom locking pin only. 3. Install spring over dampener and swing assembly up so upper locking pin can be installed. Install components. Be sure flats on the spring seats are facing in the proper locations. The spring seat end should be located next to the notch or step in the seats (upper and lower). 4. Turn forcing screw. When threads on dampener shaft are visible, install nut. 5. Tighten nut. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8731 ^ Tighten coil Over Shock absorber upper mount to shock nut 20 Nm (15 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8732 Suspension Strut / Shock Absorber: Service and Repair Strut Modification Prior to performing a camber adjustment, the lower strut-to-knuckle hole on the strut must be elongated to allow the knuckle to be moved. For appearance reasons and corrosion protection, it is important that the area filed should be painted after modification with a rust preventative paint. Strut modification can be performed on or off vehicle. 1. If the strut is on the vehicle, disconnect the strut from knuckle. If strut is off the vehicle, place strut in vise. 2. File lower hole until outer flange slot matches inner flange slot. 3. Reconnect strut to knuckle and check wheel alignment. 4. Adjust camber if necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8733 Suspension Strut / Shock Absorber: Service and Repair Strut Assembly ^ Tool Required: J 24319-01 Tie Rod End Puller - Or Equivalent REMOVE OR DISCONNECT 1. Nuts and bolt attaching top of strut assembly to body. 2. Raise vehicle and suitably support. 3. Place jack stands under front crossmember. 4. Lower vehicle slightly so the weight of the vehicle rests on the jack stands and not the control arms. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8734 5. Tire and wheel assembly. NOTICE: Care must be exercised to prevent the drive axle joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of internal components and possible joint failure. Drive axle joint boot protectors should be used any time service is performed on or near the drive axles. Failure to observe this can result in interior joint or boot damage and possible joint failure. 6. Brake line bracket. 7. Nut, and separate tie rod end from strut assembly using J 24319-01. 8. Scribe strut flange. 9. Bolts attaching strut to steering knuckle. 10. Strut assembly from vehicle. NOTICE: Care should be taken to avoid chipping or scratching the spring coating when handling the front suspension coil spring. Damage to the coating can cause premature failure. Important: Steering knuckle must be supported to prevent axle joint over-extension. INSTALL OR CONNECT NOTICE: Care should be taken to avoid chipping or scratching the spring coating when handling the front suspension coil spring. Damage to the coating can cause premature failure. 1. Strut into position and install two nuts and one bolt connecting strut assembly to body. 2. Align steering knuckle with strut flange scribe mark and install bolts and nuts. ^ Tighten nuts to 180 Nm (133 ft. lbs.). 3. Tie rod end into strut assembly and install tie rod end nut. ^ Tighten tie rod end nut to 20 Nm (15 ft. lbs.) plus 90° rotation. 4. Tighten nuts and bolt attaching top of strut assembly to body to specifications. ^ Tighten: Nuts to 25 Nm (18 ft. lbs.). - Bolt to 25 Nm (18 ft. lbs.). 5. Brake line bracket. 6. If suspension contact hoist is used: ^ Slightly raise vehicle. ^ Remove jack stands from under crossmember. 7. Tire and wheel assembly. 8. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8735 Suspension Strut / Shock Absorber: Service and Repair Coil-Over Shock Absorber REMOVE OR DISCONNECT 1. Open rear compartment. 2. Coil-over shock absorber upper shock absorber attaching nut. Remove one coil-over shock at a time when both coil-over shocks are to be replaced. 3. Raise vehicle on hoist and support rear axle with adjustable jackstands. A. When lifting vehicle with body hoist, it will be necessary to support rear axle with adjustable jackstands. B. When lifting vehicle with suspension hoist, it will be necessary to support rear axle with adjustable jackstands. 4. Bolts from coil-over shock upper mount. 5. Coil-over shock mounting bolt. Remove coil-over shock. NOTICE: Do not remove both shock absorbers at one time as suspending rear axle at full length could result in damage to brake pipes and hoses. INSTALL OR CONNECT 1. Coil-over shock absorbers at lower attachment. Install bolt hand tight. 2. Bolts to coil-over shock upper mount. 3. Lower vehicle. 4. Coil-over shock upper mount attaching nut. 5. Tighten coil-over shock lower attachment bolt to specification. ^ Tighten: Coil-over shock absorber lower mounting bolts to 170 Nm (125 ft. lbs.). - Coil-over shock absorber upper mount bolts and nut 28 Nm (21 ft. lbs.). 6. Remove axle support and lower vehicle all the way then tighten shock absorber upper nut. Coil-Over Shock Absorber Lower Adapter Bracket Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8736 REMOVE OR DISCONNECT 1. Coil-over shock absorber lower nut. 2. Coil-over shock lower adapter bolt and nut. INSTALL OR CONNECT 1. Coil-over shock lower adapter and bolt. 2. Shock absorber lower nut. ^ Tighten coil-over shock absorber adapter nut 70 Nm (52 ft. lbs.). Unit Repair Shock Absorber Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8737 ^ Tools Required: J 3289-20 Holding Fixture - J 34013-A Strut Compressor - J 41046-Coil Over Shock Adapters - Or Equivalents DISASSEMBLE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. 1. Mount Strut Compressor J 34013 in Holding Fixture J 3289-20. 2. Mount Coil-over shock into Strut Compressor. Notice that Strut Compressor has strut mounting holes drilled for specific car line. The adapter plate J 41046 must be installed first. 3. Compress Coil-over shock approximately 1/2 its height after initial contact with top cap. NEVER BOTTOM SPRING OR DAMPENER ROD. 4. Remove the nut from the Coil-over shock dampener shaft. Remove components. ASSEMBLE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. 1. Install bearing cap into Strut Compressor if previously removed. 2. Mount Coil-over shock into Strut Compressor using bottom locking pin only. 3. Install spring over dampener and swing assembly up so upper locking pin can be installed. Install components. Be sure flats on the spring seats are facing in the proper locations. The spring seat end should be located next to the notch or step in the seats (upper and lower). 4. Turn forcing screw. When threads on dampener shaft are visible, install nut. 5. Tighten nut. ^ Tighten coil Over Shock absorber upper mount to shock nut 20 Nm (15 ft. lbs.). Strut Modification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8738 Prior to performing a camber adjustment, the lower strut-to-knuckle hole on the strut must be elongated to allow the knuckle to be moved. For appearance reasons and corrosion protection, it is important that the area filed should be painted after modification with a rust preventative paint. Strut modification can be performed on or off vehicle. 1. If the strut is on the vehicle, disconnect the strut from knuckle. If strut is off the vehicle, place strut in vise. 2. File lower hole until outer flange slot matches inner flange slot. 3. Reconnect strut to knuckle and check wheel alignment. 4. Adjust camber if necessary. Strut Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8739 ^ Tool Required: J 24319-01 Tie Rod End Puller - Or Equivalent REMOVE OR DISCONNECT 1. Nuts and bolt attaching top of strut assembly to body. 2. Raise vehicle and suitably support. 3. Place jack stands under front crossmember. 4. Lower vehicle slightly so the weight of the vehicle rests on the jack stands and not the control arms. 5. Tire and wheel assembly. NOTICE: Care must be exercised to prevent the drive axle joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of internal components and possible joint failure. Drive axle joint boot protectors should be Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8740 used any time service is performed on or near the drive axles. Failure to observe this can result in interior joint or boot damage and possible joint failure. 6. Brake line bracket. 7. Nut, and separate tie rod end from strut assembly using J 24319-01. 8. Scribe strut flange. 9. Bolts attaching strut to steering knuckle. 10. Strut assembly from vehicle. NOTICE: Care should be taken to avoid chipping or scratching the spring coating when handling the front suspension coil spring. Damage to the coating can cause premature failure. Important: Steering knuckle must be supported to prevent axle joint over-extension. INSTALL OR CONNECT NOTICE: Care should be taken to avoid chipping or scratching the spring coating when handling the front suspension coil spring. Damage to the coating can cause premature failure. 1. Strut into position and install two nuts and one bolt connecting strut assembly to body. 2. Align steering knuckle with strut flange scribe mark and install bolts and nuts. ^ Tighten nuts to 180 Nm (133 ft. lbs.). 3. Tie rod end into strut assembly and install tie rod end nut. ^ Tighten tie rod end nut to 20 Nm (15 ft. lbs.) plus 90° rotation. 4. Tighten nuts and bolt attaching top of strut assembly to body to specifications. ^ Tighten: Nuts to 25 Nm (18 ft. lbs.). - Bolt to 25 Nm (18 ft. lbs.). 5. Brake line bracket. 6. If suspension contact hoist is used: ^ Slightly raise vehicle. ^ Remove jack stands from under crossmember. 7. Tire and wheel assembly. 8. Check front wheel alignment. Unit Repair Suspension Strut Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8741 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8742 ^ Tools Required: J 3289-20 Holding Fixture - J 34013-47 Template - J 34013-A Strut Compressor - J 34013-20 Dampener Rod Clamp - J 34013-27 Alignment Rod - Or Equivalents DISASSEMBLE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause premature failure. 1. Mount Strut Compressor J 34013 in Holding Fixture J 3289-20. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8743 2. Mount strut into Strut Compressor. Notice that Strut Compressor has strut mounting holes drilled for specific car line. 3. Compress strut approximately 1/2 its height after initial contact with top cap. NEVER BOTTOM SPRING OR DAMPENER ROD. 4. Remove the nut from the strut dampener shaft and place J 34013-27 Guiding Rod on top of the dampener shaft. Use this rod to guide the dampener shaft straight down through the bearing cap while decompressing the spring. Remove components. ASSEMBLE NOTICE: Care should be taken to avoid scratching or cracking the spring coating when handling the front suspension coil spring. Damage can cause Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > On-Vehicle Service > Page 8744 premature failure. 1. Install bearing cap into Strut Compressor if previously removed. 2. Mount strut into Strut Compressor using bottom locking pin only. Extend dampener shaft and install clamp J 34013-20 on dampener shaft. 3. Install spring over dampener and swing assembly up so upper locking pin can be installed. Install upper insulator, shield, bumper, and upper spring seat. Be sure flat on upper spring seat is facing in the proper direction. The spring seat flat should be facing the same direction as the centerline of strut assembly spindle. 4. Install J 34013-27 and turn forcing screw while J 34013-27 centers the assembly. When threads on dampener shaft are visible, remove J 34013-27 and install nut. 5. Tighten nut to 70 Nm (52 ft. lbs.). Use a line wrench while holding dampener shaft with socket. 6. Remove clamp. Strut and Knuckle Scribing 1. Using a sharp tool, scribe the knuckle along the lower outboard strut radius as shown. 2. Scribe the strut flange on the inboard side along the curve of the knuckle, as shown. 3. Make a scribe mark across the strut/knuckle interface as shown. 4. On reassembly, carefully match the marks to the components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Technical Service Bulletins > Recalls for Trailing Arm: > NHTSA98V319000 > Dec > 98 > Recall 98V319000: Suspension Trailing Arm Bolt Defect Trailing Arm: Recalls Recall 98V319000: Suspension Trailing Arm Bolt Defect Vehicle Description: Passenger vehicles. One of the rear suspension trailing arm bolts can fatigue and break. If this were to occur while the vehicle was in motion, a loss of vehicle control can occur, increasing the risk of a crash. Dealers will replace the rear suspension trailing arm fasteners. Owner notification began December 28, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailing Arm: > NHTSA98V319000 > Dec > 98 > Recall 98V319000: Suspension Trailing Arm Bolt Defect Trailing Arm: All Technical Service Bulletins Recall 98V319000: Suspension Trailing Arm Bolt Defect Vehicle Description: Passenger vehicles. One of the rear suspension trailing arm bolts can fatigue and break. If this were to occur while the vehicle was in motion, a loss of vehicle control can occur, increasing the risk of a crash. Dealers will replace the rear suspension trailing arm fasteners. Owner notification began December 28, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 8761 Wheel Bearing: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 8762 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension FRONT WHEEL BEARINGS AND/OR HUB ^ Tools Required: J 28733-A Front Hub Spindle Remover REMOVE OR DISCONNECT 1. Drive axle. 2. Brake caliper bolts, and support caliper. 3. Rotor. 4. Hub and bearing assembly. 5. Hub and bearing assembly from steering knuckle. 6. Hub and bearing. INSTALL OR CONNECT 1. Hub and bearing assembly to steering knuckle. 2. Hub and bearing assembly bolts. ^ Tighten hub and bearing assembly bolts to 95 Nm (70 ft. lbs.). 3. Rotor. 4. Brake caliper and bolts. 5. New hub and bearing into steering knuckle. 6. Drive axle. 7. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 8765 Wheel Bearing: Service and Repair Rear Suspension REAR WHEEL BEARINGS AND/OR HUB REMOVE OR DISCONNECT 1. Raise vehicle. 2. Wheel and tire assemblies. 3. Brake drum. NOTICE: Do not hammer on brake drum as damage to the assembly could result. 4. Rear ABS wheel speed sensor wire connector. 5. Remove hub and bearing assembly from axle. The top rear attaching bolt/nut will not clear the brake shoe when removing the hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. INSTALL OR CONNECT 1. Connect rear ABS wheel speed sensor wire connector. 2. Hub and Bearing assembly. Position top rear attaching bolt in hub and bearing assembly prior to the installation in the axle assembly. ^ Tighten hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). 3. Brake drum. 4. Wheel and tire assembly. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Steering - Various Revised Tightening Specifications Axle Nut: Technical Service Bulletins Steering - Various Revised Tightening Specifications CHEVROLET 73-32-03A Issued: 05/01/97 SMU - SECTIONS 3B/3C/4D REVISION: 04/11/97 THIS BULLETIN IS BEING REVISED TO UPDATE THE DRIVE AXLE NUT TIGHTENING SPECIFICATIONS FOR THE N CAR. PLEASE DISCARD CORPORATE BULLETIN NUMBER 73-32-03 (SECTION 3 - STEERING/SUSPENSION). SUBJECT: SERVICE MANUAL UPDATE - SECTIONS 3B/3C/4D - REVISED TIGHTENING SPECIFICATIONS MODELS: 1997 CHEVROLET CAVALIER, MALIBU 1997 OLDSMOBILE CUTLASS 1997 PONTIAC SUNFIRE THIS BULLETIN IS BEING ISSUED TO REVISE THE TIGHTENING SPECIFICATIONS IN SECTIONS 3B, 3C AND 4D OF THE SERVICE MANUAL AS FOLLOWS: J CAR SECTIONS 3B-8, 3B-9, 3C-5 AND 3C-13: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 90 DEGREE ROTATION. N CAR SECTIONS 3C-6 AND 3C-16: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 180 DEGREE ROTATION. SECTION 3B-12: THE CORRECT TIGHTENING SPECIFICATIONS ARE AS FOLLOWS: - STEERING COLUMN LOWER PINCH BOLT 22 N.M (16 LB FT) - STEERING COLUMN UPPER PINCH BOLT 22 N.M (16 LB FT) SECTIONS 3C-16, 4D-4 AND 4D-5: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - FRONT DRIVE AXLE NUT 385 N.M (284 LB FT) +/- 5 N.M (44 LB IN). REPLACE THE DRIVE AXLE NUT WITH A NEW ONE AFTER EVERY REMOVAL. NEVER RE-USE THE DRIVE AXLE NUT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 8771 Axle Nut: Specifications Service Manual Update # 73-32-03A Drive Axle Nut (New) ............................................................................................................................................... 385 Nm (284 lb ft) +/- 5 Nm (44 lb in) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair GENERAL VEHICLE LIFTING AND JACKING CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. The additional support will reduce the possibility of the vehicle falling off the hoist. When removing major components from the vehicle while the vehicle is on a hoist, the vehicle frame should be chained to the hoist pads at the same end as the removed components to prevent tip-off. Failure to follow these precautionary measures could result in vehicle damage, serious personal injury, or death. NOTICE: When jacking or lifting a vehicle at prescribed lift points, be certain that lift pads do not contact the exhaust system, brake pipes, cables, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Recalls for Spare Tire: > NHTSA97V106000 > Jun > 97 > Recall 97V106000: Compact Spare Tire Rim Replacement Spare Tire: Recalls Recall 97V106000: Compact Spare Tire Rim Replacement The compact spare tire assemblies were assembled with incorrect rims. If the spare tire is underinflated, the bead can separate from the rim causing a rapid loss of air. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." A rapid loss of air can increase the risk of a vehicle crash. Dealers will replace the rim on the compact spare tire assembly. Owners are requested not to use the spare tire until the rim has been replaced. Owner Notification: Owner notification will begin during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER 1997 PONTIAC SUNFIRE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spare Tire: > NHTSA97V106000 > Jun > 97 > Recall 97V106000: Compact Spare Tire Rim Replacement Spare Tire: All Technical Service Bulletins Recall 97V106000: Compact Spare Tire Rim Replacement The compact spare tire assemblies were assembled with incorrect rims. If the spare tire is underinflated, the bead can separate from the rim causing a rapid loss of air. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." A rapid loss of air can increase the risk of a vehicle crash. Dealers will replace the rim on the compact spare tire assembly. Owners are requested not to use the spare tire until the rim has been replaced. Owner Notification: Owner notification will begin during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER 1997 PONTIAC SUNFIRE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 8790 Spare Tire: Service and Repair All vehicles will be equipped with a high pressure compact spare. The compact spare uses a narrow 4-inch wide rim, although the wheel diameter is usually one inch larger than the road wheels. The compact spare wheel should not be used with standard tires, snow tires, wheel covers or trim rings. If such use is attempted, damage to these items or other parts of the vehicle may occur. The compact spare should be used only on vehicles which offered it as original equipment. CAUTION: To avoid serious personal injury do not stand over tire when inflating. Bead may break when bead snaps over safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 pal) pressure will not seat beads, deflate, lubricate the beads and reinflate. Over-inflation may cause the bead to break and cause serious personal Injury. Inflation pressure of the compact spare must be periodically checked and maintained at 415 kPa (60 psi). It can be mounted and dismounted from its wheel using present tire changing equipment and procedures. As with other tires, the beads should completely seat at 275 kPa (40 psi). The tire may then be safely inflated to 415 kPa (60 psi). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8799 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8800 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8801 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 8806 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8812 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8813 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8814 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 8819 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8824 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8825 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8830 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8831 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 8832 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 8837 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8855 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8856 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 8857 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 8862 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8867 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 8868 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8881 Wheels: Specifications Maximum Lateral Runout: Aluminum Wheels ................................................................................................................................ ........................................... 0.76 mm (0.030 inch) Steel Wheels ........................................................ ............................................................................................................................ 1.14 mm (0.045 inch) Maximum Radial Runout: Aluminum Wheels ................................................................................................................................ ........................................... 0.76 mm (0.030 inch) Steel Wheels ........................................................ ............................................................................................................................ 1.01 mm (0.040 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information Wheels: Technician Safety Information WARNING: This vehicle has a Supplemental Inflatable Restraint (SIR) System. Refer to the SIR Component and Wiring Location view in order to determine whether you are performing service on or near the SIR components or the SIR wiring. When you are performing service on or near the SIR components or the SIR wiring, refer to the SIR On-Vehicle Service information. Failure to follow the WARNINGS could cause air bag deployment, personal injury, or unnecessary SIR system repairs. WARNING: To help avoid personal Injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle slipping from the hoist. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service Precautions > Technician Safety Information > Page 8884 Wheels: Vehicle Damage Warnings NOTICE: Always use the correct fastener in the correct location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > General Information Wheels: Description and Operation General Information The factory installed tires and wheels are designed to operate with loads up to and including the full rated load capacity when inflated to the recommended inflation pressures. Correct tire pressures, wheel alignment and driving techniques have an important influence on tire life. Heavy cornering, excessive rapid acceleration, and heavy braking will increase tire wear. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > General Information > Page 8887 Wheels: Description and Operation Wheels Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, leak air through welds, have elongated bolt holes, if wheel nuts won't stay tight, or if they are heavily rusted. Wheels with excessive runout may cause objectional vibrations. Replacement wheels must be equivalent to the original equipment wheels in load capacity, diameter, rim width, offset, and mounting configuration. A wheel of improper size or type may affect wheel and bearing life, brake cooling, speedometer/odometer calibration, vehicle ground clearance, and tire clearance to the body and chassis. Steel wheels can be identified by a two or three-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, part number, and manufacturer ID cast into their back side. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 8888 Wheels: Testing and Inspection Wheel runout should be measured with an accurate dial indicator. Measurements may be taken with the wheel installed on the vehicle, or off the vehicle using an accurate mounting surface such as on a wheel balancer. Measurements may also be taken with or without the tire mounted on the wheel. Radial runout and lateral runout should be measured on both the inboard and outboard rim flanges. With the dial indicator firmly in position, slowly rotate the wheel one revolution and record the total indicator reading. If any measurement exceeds specifications, and there is a vibration that wheel balancing will not correct, the wheel should be replaced. Disregard any indicator readings due to welds, paint runs, scratches, etc. ^ STEEL WHEELS - Radial runout 1.01 mm (0.040 inch) - Lateral runout 1.14 mm (0.045 inch) ^ ALUMINUM WHEELS - Radial runout 0.76 mm (0.030 inch) - Lateral runout 0.76 mm (0.030 inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service Wheels: Service and Repair On-Vehicle Service Wheel Removal GENERAL INFORMATION Penetrating oil has not been found to be effective in removing tight wheels. However, if it is used, it should be applied sparingly to the wheel center hole area only. CAUTION: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum, It could cause the wheel to work loose as the vehicle Is driven, resulting in a loss of control and an injury accident. Never use heat to loosen-a tight wheel. It can shorten the life of the wheel, studs or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the proper fastener tightening specification to avoid bending the wheel or rotor. Sometimes wheels can be difficult to remove due to foreign material or a tight fit between the wheel center hole and the rotor. Excessive force such as hammering the wheel or tire can cause damage and is not recommended. Slight tapping on the tire sidewall using a large rubber mallet is acceptable. The wheel can be removed without damage as follows: 1. Tighten all wheel nuts on the affected wheel. Then loosen each nut two turns. Rock the vehicle side to side. If this is not effective, go to step 2. Rock the vehicle from "DRIVE" to "REVERSE" allowing the vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal to loosen the wheel. If the wheel still does not free up, then rock the vehicle again from side to side as hard as possible using one or more persons' body weight. If the wheel is still tight, repeat the procedure. REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Wheel cover, if equipped. 3. Wheel nuts. ^ Mark location of tire and wheel assembly to hub assembly. ^ Clean wheel nuts, studs and the wheel and brake drum or rotor mounting surfaces. CAUTION: Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface and brake drum or rotor by scraping and wire brushing. Installing wheels without good metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen, which may later allow the wheel to come off while the vehicle is in motion. Wheel Installation INSTALL OR CONNECT 1. Hub cap on aluminum wheel, if removed. 2. Tire and wheel assembly. ^ Align locating mark of tire and wheel to hub assembly. NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for the application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener tightening specification and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. CAUTION: Never use oil or grease on studs or nuts. Tighten the wheel nuts with your fingers until they are snug. Then, tighten the Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 8891 nuts (in the sequence shown) to the fastener tightening specification shown in "Specifications". Improperly tightened wheel nuts could eventually allow the wheel to come off while the vehicle is moving, possibly causing loss of control, personal injury and property damage. 3. Wheel nuts. ^ Tighten wheel nuts in sequence to 140 Nm (100 ft. lbs.). 4. Wheel cover, if equipped. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 8892 Wheels: Service and Repair Aluminum Wheels - Additional Information Aluminum Wheel Hub Cap REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Tire and wheel assembly. 3. Hub cap. ^ Place a block of wood approximately 50 mm (2 inches) in diameter with a squared off end against the back surface of the cap. A sharp hammer blow on the block of wood will remove the cap. INSTALL OR CONNECT 1. Hub cap ^ Place cap into position at wheel opening and place a block of wood at least 75 mm (3 inches) on diameter against cap face. Install cap by striking block of wood with hammer. NOTICE: Failure to hit cap squarely without the load distributed evenly could result in permanent damage to the cap. 2. Tire and wheel assembly. Aluminum Wheel Porosity Repair 1. Raise vehicle and suitably support. 2. Remove tire and wheel assembly. 3. Locate leaking areas by inflating tire to 275 kPa (40 psi) and dipping tire and wheel assembly into a water bath. 4. Mark leak areas and remove tire from wheel. 5. Scuff inside rim surface at leak area with 80 number grit sandpaper and clean area with general purpose cleaner such as 3M P/N 08984 or equivalent. 6. Apply 3 mm (1/8 inch) thick layer of adhesive/sealant P/N 1052366 or equivalent to leak area and allow six hours of drying time. CAUTION: To avoid serious personal injury, do not stand over tire when inflating. Bead may break when bead snaps over safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat beads, deflate, lubricate the beads and reinflate. Over-inflation may cause the bead to break and cause serious personal Injury. 7. Mount tire on wheel, pressurize to 275 kPa (40 psi) and check for leaks. 8. Adjust tire pressure to meet specifications. 9. Balance tire and wheel assembly. 10. Install tire and wheel assembly. Aluminum Wheel Refinishing GENERAL PROCEDURE A protective clear or color coating is applied to the surface of original equipment cast aluminum wheels. A surface degradation condition can begin to develop if this clear coating is damaged or removed. This can happen at some automatic car wash facilities using aggressive silicon carbide tipped tire brushes to clean white walls and tires. Once the protective coating is damaged, exposure to caustic cleaners and/or road salt further causes surface degradation. The following procedure details how to strip, clean and coat aluminum wheels that are affected by these conditions. ^ Required Materials: - Amchem Alumi Prep number 33 - stock number DX533 or equivalent - cleaning and conditioning chemical for aluminum. - Amchem Alodine number 1001 - stock number DXSOT or equivalent - coating chemical for aluminum. - Ditzler Delclear Acrylic Urethane Clear - stock number DAU-75 or equivalent. - Ditzler Delthane Ultra-Urethane Additive - stock DXR-80 or equivalent. INITIAL PREPARATION Remove Or Disconnect 1. Wheel and tire assembly from the vehicle. ^ Match mark tire for reinstallation of outboard wheel weights after re-coating of wheel. 2. Outboard wheel weights. ^ Clean wheel inside and out with a water base all purpose cleaner. Remove grease or oil with a solvent cleaner. ACCENT COLOR PREPARATION Sand over painted areas that do not require recoloring with number 400 grit (wet or dry) to promote adhesion of clear coat. SURFACE DAMAGE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 8893 CAUTION: Do not use vehicle power to rotate the wheel while sanding or personal injury may result. 1. Mount tire and wheel on brake lathe and spin slowly. NOTICE: Do not use abrasive coarser than 80 grit or wheel may be damaged. 2. Sand wheel with backing block or pad by holding abrasive flat to surface of wheel and moving slowly back and forth from center to outer edge to remove damage. Use the following sandpaper grits in the order listed. A. Sand with number 80 grit sandpaper. B. Sand with number 150 grit sandpaper. C. Sand with number 240 grit sandpaper. 3. Continue with "Re-coating Procedure." CLEAR COAT DAMAGE ON UNPAINTED WHEELS CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal Injury. 1. Apply chemical stripper. ^ Allow stripper to penetrate coating. ^ Use small 1/4 inch detail brush dipped in stripper to apply material around perimeter and spoke-like areas. 2. Remove stripper following manufacturers recommendations. CAUTION: Do not use vehicle power to rotate the wheel while sanding or personal injury may result. 3. Sand wheel with 240 grit while rotating wheel on a slow spinning brake lathe or by mounting on vehicle and spinning by hand. This will restore the machined appearance and promote adhesion. 4. Continue with "Re-coating Procedure." RE-COATING PROCEDURE CAUTION: Use of rubber gloves and eye protection is necessary to prevent personal Injury. 1. Clean surface of contaminants by washing with soap and water. 2. Spray the wheel with Amchem number 33 or equivalent. ^ Let the wheel soak for 1 to 3 minutes. ^ Rinse the wheel with water and blow dry. 3. Soak wheel with Amchem #1001 or equivalent. ^ Let the wheel soak for 1 to 3 minutes. ^ Rinse the wheel with water and blow dry. 4. Mask off the tire. CAUTION: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 5. Finish the wheel with Ditzler Delclear Acrylic Urethane and Ditzler Ultra-Urethane Additive or equivalent using three coats. Refer to labels for specific directions. ^ First Coat - Light mist coat, let flash. ^ Second Coat Light, let flash. ^ -Third Coat - Heavy double wet coat. 6. Let the wheel dry for 24 hours - (or flash for 30 minutes, force dry at 60° C (140° F) for 30 minutes, and allow to cool for 30 minutes before mounting. INSTALL OR CONNECT 1. Balance wheel and tire assembly. ^ Replace the original balance weights with nylon coated weights to avoid discoloration of the wheel. 2. Tire and wheel assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 8894 Wheels: Service and Repair Wheel Repair Wheel repairs that use welding, heating, or peening are not approved. An inner tube is not an acceptable repair for leaky wheels or tires. Porosity in aluminum wheels can be repaired, refer to "Aluminum Wheel Porosity Repair." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 8895 Wheels: Service and Repair Balancing Tire and Wheel GENERAL INFORMATION There are two types of tire and wheel balancing, static and dynamic. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called wheel tramp. This condition may eventually cause uneven tire wear Dynamic balance is the equal distribution of weight on each side of the centerline so that when the assembly spins there is no tendency for it to move from side to side. Assemblies that are dynamically unbalanced may cause wheel shimmy. GENERAL BALANCE PRECAUTIONS Deposits of foreign material must be cleaned from the inside of the wheel. When balancing aluminum and composite wheels the balancer pressure cup should have a protective plastic or rubber edge on it to avoid damaging the rim surface finish. Stones should be removed from the tread in order to avoid operator injury during spin balancing and to obtain a good balance. The tire should be inspected for any damage, then balanced according to the equipment manufacturer's recommendations. OFF-VEHICLE BALANCING Wheel balancing should be performed using an electronic off-vehicle balancer. They are easy to use and give both a static and a dynamic balance. Although they do not correct for drum or rotor unbalance as does on-vehicle spin balancing, this is overcome by their accuracy (usually to within 1/8 ounce). When balancing off-vehicle, the wheel should locate on the balancer with a cone through the back side of the center pilot hole (not by the wheel stud holes). ON-VEHICLE BALANCING Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > On-Vehicle Service > Page 8896 When needed, on-vehicle balancing will help correct vibrations due to brake drum, rotor, and wheel cover imbalance. The front suspension should not be allowed to hang free. When the CV joint is run at a very high angle, extra vibrations can occur, resulting in damage to boots and joints. Always follow the equipment manufacturer's instructions. When balancing on-vehicle, do not remove the balance weights from the off-vehicle dynamic balance. If more than one ounce of additional weight is required, it should be split between the inner and outer rim flange. NOTICE: The driven tire and wheel assemblies should be spun using the engine. Limit speed as stated in the following Caution. CAUTION: Do not spin the drive wheels faster than 55 km/h (35 mph) as indicated by the speedometer. This limit is necessary because the speedometer indicates only one-half of the actual wheel speed when one drive wheel is spinning and the other drive wheel is stopped. Personal injury and damage may result from high speed spinning. WHEEL BALANCE WEIGHTS When static balancing, if more than 40 grams (1.0 oz.) are needed, the wheel weights should be split as equal as possible between the inboard and outboard flanges. Balancing factory aluminum wheels requires the use of special nylon coated clip-on wheel weights. These weights are designed to fit over the thicker rim flange of the aluminum wheel and should be installed with a plastic tipped hammer. Adhesive wheel weights are also available. Use the following procedure to install adhesive wheel weights. ADHESIVE WHEEL WEIGHT INSTALLATION 1. Clean wheel by sanding to bare aluminum where wheel weight is to be located. 2. Wipe wheel weight attachment area with a mixture of half Isopropyl alcohol and half water. A clean cloth or paper towel must be used for this operation. 3. Dry the attachment area with hot air. Surface of wheel should be warm to the touch. 4. The adhesive backing on wheel weights must be warmed to room temperature. 5. Remove tape from back of weights. Do not touch the adhesive surface. 6. Apply wheel weight and press on with hand pressure. 7. Secure wheel weight with a 70-110 N (16-25 lbs.) force applied with a roller. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications This vehicle uses a sealed wheel bearing and lubricating grease is not required. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8900 Wheel Bearing: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8901 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension FRONT WHEEL BEARINGS AND/OR HUB ^ Tools Required: J 28733-A Front Hub Spindle Remover REMOVE OR DISCONNECT 1. Drive axle. 2. Brake caliper bolts, and support caliper. 3. Rotor. 4. Hub and bearing assembly. 5. Hub and bearing assembly from steering knuckle. 6. Hub and bearing. INSTALL OR CONNECT 1. Hub and bearing assembly to steering knuckle. 2. Hub and bearing assembly bolts. ^ Tighten hub and bearing assembly bolts to 95 Nm (70 ft. lbs.). 3. Rotor. 4. Brake caliper and bolts. 5. New hub and bearing into steering knuckle. 6. Drive axle. 7. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 8904 Wheel Bearing: Service and Repair Rear Suspension REAR WHEEL BEARINGS AND/OR HUB REMOVE OR DISCONNECT 1. Raise vehicle. 2. Wheel and tire assemblies. 3. Brake drum. NOTICE: Do not hammer on brake drum as damage to the assembly could result. 4. Rear ABS wheel speed sensor wire connector. 5. Remove hub and bearing assembly from axle. The top rear attaching bolt/nut will not clear the brake shoe when removing the hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. INSTALL OR CONNECT 1. Connect rear ABS wheel speed sensor wire connector. 2. Hub and Bearing assembly. Position top rear attaching bolt in hub and bearing assembly prior to the installation in the axle assembly. ^ Tighten hub and bearing to axle bolts to 60 Nm (44 ft. lbs.). 3. Brake drum. 4. Wheel and tire assembly. 5. Lower vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Tire and wheel assembly. 3. Hub cap. ^ Place a block of wood approximately 50 mm (2 inches) in diameter with a squared off end against the back surface of the cap. A sharp hammer blow on the block of wood will remove the cap. INSTALL OR CONNECT 1. Hub cap ^ Place cap into position at wheel opening and place a block of wood at least 75 mm (3 inches) on diameter against cap face. Install cap by striking block of wood with hammer. NOTICE: Failure to hit cap squarely without the load distributed evenly could result in permanent damage to the cap. 2. Tire and wheel assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Steering - Various Revised Tightening Specifications Axle Nut: Technical Service Bulletins Steering - Various Revised Tightening Specifications CHEVROLET 73-32-03A Issued: 05/01/97 SMU - SECTIONS 3B/3C/4D REVISION: 04/11/97 THIS BULLETIN IS BEING REVISED TO UPDATE THE DRIVE AXLE NUT TIGHTENING SPECIFICATIONS FOR THE N CAR. PLEASE DISCARD CORPORATE BULLETIN NUMBER 73-32-03 (SECTION 3 - STEERING/SUSPENSION). SUBJECT: SERVICE MANUAL UPDATE - SECTIONS 3B/3C/4D - REVISED TIGHTENING SPECIFICATIONS MODELS: 1997 CHEVROLET CAVALIER, MALIBU 1997 OLDSMOBILE CUTLASS 1997 PONTIAC SUNFIRE THIS BULLETIN IS BEING ISSUED TO REVISE THE TIGHTENING SPECIFICATIONS IN SECTIONS 3B, 3C AND 4D OF THE SERVICE MANUAL AS FOLLOWS: J CAR SECTIONS 3B-8, 3B-9, 3C-5 AND 3C-13: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 90 DEGREE ROTATION. N CAR SECTIONS 3C-6 AND 3C-16: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - TIE ROD END TO KNUCKLE NUT 20 N.M (15 LB FT) PLUS 180 DEGREE ROTATION. SECTION 3B-12: THE CORRECT TIGHTENING SPECIFICATIONS ARE AS FOLLOWS: - STEERING COLUMN LOWER PINCH BOLT 22 N.M (16 LB FT) - STEERING COLUMN UPPER PINCH BOLT 22 N.M (16 LB FT) SECTIONS 3C-16, 4D-4 AND 4D-5: THE CORRECT TIGHTENING SPECIFICATION IS AS FOLLOWS: - FRONT DRIVE AXLE NUT 385 N.M (284 LB FT) +/- 5 N.M (44 LB IN). REPLACE THE DRIVE AXLE NUT WITH A NEW ONE AFTER EVERY REMOVAL. NEVER RE-USE THE DRIVE AXLE NUT. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 8913 Axle Nut: Specifications Service Manual Update # 73-32-03A Drive Axle Nut (New) ............................................................................................................................................... 385 Nm (284 lb ft) +/- 5 Nm (44 lb in) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 8922 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 8928 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque Wheel Fastener: Specifications Tightening Torque All Wheels Nuts ................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Torque > Page 8931 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Application and ID > Metric Wheel Nuts and Bolts Wheel Fastener: Application and ID Metric Wheel Nuts and Bolts All models use metric wheel nuts and wheel studs. The nut will have the word "metric" stamped on the face and the stud will have the letter "M" stamped into the threaded end. The word "metric" is stamped on the head. The thread size of the metric wheel nuts and wheel studs are "M 12 x 1.5". This signifies: M = Metric 12 = Diameter in millimeters 1.5 = Millimeters per thread If a broken stud is found, refer to "Front Suspension" or "Rear Suspension" for replacement procedure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Application and ID > Metric Wheel Nuts and Bolts > Page 8934 Wheel Fastener: Application and ID Metric Wheel Nuts and Studs All models use metric wheel nuts and wheel studs. The nut will have the word "metric" stamped on the face and the stud will have the letter "M" stamped into the threaded end. The word "metric" is stamped on the head. The thread size of the metric wheel nuts and wheel studs are "M 12 x 1.5". This signifies: M = Metric 12 = Diameter in millimeters 1.5 = Millimeters per thread If a broken stud is found, refer to "Front Suspension" or "Rear Suspension" for replacement procedure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension ^ Tools Required: J 6627-A Wheel Stud Remover - J 28733-A Front Hub Spindle Remover. - Or Equivalents REMOVE OR DISCONNECT 1. Hub and bearing assembly. 2. Wheel stud from hub and bearing assembly using tool J 6627-A. Discard stud. INSTALL OR CONNECT 1. New wheel stud into hub and bearing assembly. 2. Flat washers and nut (flat side down) onto wheel stud, and tighten until wheel stud is fully seated. 3. Hub and bearing assembly. 4. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 8937 Wheel Fastener: Service and Repair Rear Suspension ^ Tool Required: J 6627-A Wheel Stud Remover - Or Equivalent REMOVE OR DISCONNECT 1. Wheel and tire assembly. 2. Brake drum. NOTICE: Do not hammer on brake drum as damage to the bearing or deformation of the drum could result. 3. Wheel stud using tool J 6627-A. 4. Discard stud. INSTALL OR CONNECT 1. New stud (insert from back side of hub). 2. Four flat washers on stud. 3. Wheel nut (install with flat side toward washers). 4. Tighten nut until stud head is properly seated in hub flange. 5. Remove nut and washers. 6. Brake drum. 7. Wheel and tire assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Accumulator Accumulator HVAC: Specifications Accumulator A/C Accumulator Retaining Clamp Bolt .................................................................................................................................................... 8 N.m (71 lb. in.) Accumulator Bracket Nut ..................................................................................................................... .................................................... 10 N.m (89 lb. in.) Accumulator Bracket Bolt .................................................................................................................... ...................................................... 5 N.m (44 lb. in.) Accumulator Inlet Fitting ...................................................................................................................... .................................................... 24 N.m (18 lb. ft.) Accumulator Outlet Fitting ................................................................................................................... ..................................................... 24 N.m (18 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Accumulator > Page 8943 Accumulator HVAC: Specifications Accumulator Tube (Evaporator to Accumulator) Accumulator Tube at Evaporator .............................................................................................................................................................. 24 N.m (18 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8944 Accumulator HVAC: Locations Evaporator Tube And Accumulator Tube RH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 8945 Accumulator HVAC: Description and Operation Downstream of the evaporator outlet pipe, the sealed accumulator assembly functions as a liquid/vapor separator. It receives refrigerant vapor, along with some liquid refrigerant and refrigerant oil from the evaporator. It allows only refrigerant vapor and oil to pass on to the compressor. At the bottom of the accumulator is the desiccant bag. It acts as a drying agent for moisture that may have entered the system. An oil bleed hole is located near the bottom of the accumulator outlet pipe to provide an oil return path to the compressor. If the system is open to air for an extended period of time (due to a front-end collision, removed parts, etc.) replace the accumulator. The desiccant bag will be saturated with moisture. The accumulator is serviced by replacement only. The accumulator is located in the right hand corner of the engine compartment and is attached to the front of dash. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Accumulator Accumulator HVAC: Service and Repair Accumulator Accumulator Mounting The accumulator assembly service replacement part includes O-rings (as necessary) for connections. The desiccant within the shell is NOT serviced separately - it is part of the sealed accumulator assembly. The accumulator assembly should be replaced ONLY when the shell is perforated and a refrigerant leak is found, or the system has been open to the atmosphere for an extended period. Accumulators do not require periodic replacement due to the following changes: ^ Use of improved desiccant. ^ Use of improved hose material and increased use of metal lines, both of which reduces the ability of moisture to enter the refrigerant system. See "Refrigerant Oil Distribution" to determine the quantity of oil to be added to an accumulator that has been replaced. See: Specifications/Capacity Specifications Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Negative battery cable. 2. Recover refrigerant. 3. Cruise control stepper motor bracket, and position aside. (if equipped). 4. Refrigerant lines at the accumulator. Discard O-ring seals. 5. Clamp on accumulator bracket and accumulator. Install or Connect 1. Accumulator and bracket clamp. Important ^ Add required amount of new refrigerant oil, see "Refrigerant Oil Distribution." 2. Refrigerant lines at the accumulator using new O-ring seals. 3. Cruise control stepper motor bracket. 4. Negative battery cable. 5. Evacuate and charge the A/C system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Accumulator > Page 8948 Accumulator HVAC: Service and Repair Accumulator Tube (Evaporator to Accumulator) Evaporator Tube And Accumulator Tube Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Tube at accumulator and discard O-ring seal. 3. Raise vehicle. 4. Tube nut fitting at evaporator and discard O-ring seals. 5. Lower vehicle, remove tube. Install or Connect 1. Set tube in place. Raise vehicle. 2. Tube nut fitting at evaporator using new O-ring seals. 3. Lower vehicle. 4. Tube at accumulator using a new O-ring seal. 5. Evacuate and charge A/C system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator HVAC Assembly Under I/P Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator > Page 8954 HVAC Assembly Under I/P Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator > Page 8955 Air Door Actuator / Motor: Locations Vacuum Actuators With Air Conditioning HVAC Module - Disassemble View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator > Page 8956 HVAC Module - Top And Left View The vacuum actuators are located under the instrument panel and attached to the HVAC module. Image Key 1 VALVE HOUSING COVER 2 HEATER-A/C MODULE BOLTS 3 DEFROSTER VALVE 4 MODE VALVE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator > Page 8957 5 VACUUM TANK 6 HVAC MODULE BRACKET 7 HEATER-A/C CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HVAC CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER CORE COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 A/C EVAPORATOR TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER-A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLT 26 BLOWER MOTOR BOLT INSULATOR 27 BLOWER MOTOR 28 BLOWER MOTOR FAN 29 BLOWER RESISTOR 30 A/C EVAPORATOR WATER FILTER RETAINER 31 A/C EVAPORATOR WATER FILTER 32 EVAPORATOR CORE MATING SPACER 33 EVAPORATOR CORE 34 EVAPORATOR CORE SEAL 35 A/C EVAPORATOR BRACKET 36 BLOWER AND AIR INLET CASE 37 MOUNT SEAL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator > Page 8958 38 AIR INLET HOUSING 39 AIR INLET VALVE ACTUATOR 40 HEATER-A/C VACUUM HARNESS Without Air Conditioning Heater Module - Disassembled View (1 Of 2) The vacuum actuators are located under the instrument panel and attached to the HVAC module. Image Key 1 VALVE HOUSING COVER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator > Page 8959 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Defroster Valve Actuator > Page 8960 HVAC Assembly Under I/P Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning Air Door Actuator / Motor: Service and Repair With Air Conditioning Air Inlet (Recirculation) Vacuum Actuator HVAC Module - Disassemble View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8963 HVAC Module - Top And Left View The vacuum actuators are located under the instrument panel and attached to the HVAC module. Remove or Disconnect 1. Negative battery cable. 2. I/P trim pad. 3. Passenger side SIR module. 4. Vacuum hose from actuator. 5. Clip attaching actuator to the module. 6. Actuator arm from the valve. 7. Actuator from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8964 Install or Connect 1. Actuator arm to the valve. 2. Actuator to the module, snap into place. 3. Vacuum hose to the actuator. 4. Passenger side SIR module. 5. I/P trim pad. 6. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER-A/C MODULE BOLTS 3 DEFROSTER VALVE 4 MODE VALVE 5 VACUUM TANK 6 HVAC MODULE BRACKET 7 HEATER-A/C CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HVAC CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER CORE COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 A/C EVAPORATOR TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER-A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLT 26 BLOWER MOTOR BOLT INSULATOR 27 BLOWER MOTOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8965 28 BLOWER MOTOR FAN 29 BLOWER RESISTOR 30 A/C EVAPORATOR WATER FILTER RETAINER 31 A/C EVAPORATOR WATER FILTER 32 EVAPORATOR CORE MATING SPACER 33 EVAPORATOR CORE 34 EVAPORATOR CORE SEAL 35 A/C EVAPORATOR BRACKET 36 BLOWER AND AIR INLET CASE 37 MOUNT SEAL 38 AIR INLET HOUSING 39 AIR INLET VALVE ACTUATOR 40 HEATER-A/C VACUUM HARNESS Mode Valve Vacuum Actuator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8966 HVAC Module - Disassemble View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8967 HVAC Module - Top And Left View The vacuum actuators are located under the instrument panel and attached to the HVAC module. Remove or Disconnect 1. Negative battery cable. 2. Left sound insulator 3. I/P trim pad. 4. Air distribution duct. 5. Actuator and actuator rod from module. 6. Vacuum hoses from actuator. 7. Vacuum actuator from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8968 Install or Connect 1. Vacuum actuator from below. 2. Vacuum hoses to actuator. 3. Actuator rod to module (from above). 4. Air distribution duct. 5. I/P trim pad. 6. Left sound insulator. 7. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER-A/C MODULE BOLTS 3 DEFROSTER VALVE 4 MODE VALVE 5 VACUUM TANK 6 HVAC MODULE BRACKET 7 HEATER-A/C CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HVAC CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER CORE COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 A/C EVAPORATOR TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER-A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLT 26 BLOWER MOTOR BOLT INSULATOR 27 BLOWER MOTOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8969 28 BLOWER MOTOR FAN 29 BLOWER RESISTOR 30 A/C EVAPORATOR WATER FILTER RETAINER 31 A/C EVAPORATOR WATER FILTER 32 EVAPORATOR CORE MATING SPACER 33 EVAPORATOR CORE 34 EVAPORATOR CORE SEAL 35 A/C EVAPORATOR BRACKET 36 BLOWER AND AIR INLET CASE 37 MOUNT SEAL 38 AIR INLET HOUSING 39 AIR INLET VALVE ACTUATOR 40 HEATER-A/C VACUUM HARNESS Defrost Vacuum Actuator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8970 HVAC Module - Disassemble View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8971 HVAC Module - Top And Left View The vacuum actuators are located under the instrument panel and attached to the HVAC module. Remove or Disconnect 1. Negative battery cable. 2. I/P trim pad. 3. Passenger side SIR module. 4. Vacuum hose from actuator. 5. Clip attaching actuator to the module. 6. Actuator arm from the valve. 7. Actuator from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8972 Install or Connect 1. Actuator arm to the valve. 2. Actuator to the module, snap into place. 3. Vacuum hose to the actuator. 4. Passenger side SIR module. 5. I/P trim pad. 6. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER-A/C MODULE BOLTS 3 DEFROSTER VALVE 4 MODE VALVE 5 VACUUM TANK 6 HVAC MODULE BRACKET 7 HEATER-A/C CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HVAC CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER CORE COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 A/C EVAPORATOR TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER-A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLT 26 BLOWER MOTOR BOLT INSULATOR 27 BLOWER MOTOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8973 28 BLOWER MOTOR FAN 29 BLOWER RESISTOR 30 A/C EVAPORATOR WATER FILTER RETAINER 31 A/C EVAPORATOR WATER FILTER 32 EVAPORATOR CORE MATING SPACER 33 EVAPORATOR CORE 34 EVAPORATOR CORE SEAL 35 A/C EVAPORATOR BRACKET 36 BLOWER AND AIR INLET CASE 37 MOUNT SEAL 38 AIR INLET HOUSING 39 AIR INLET VALVE ACTUATOR 40 HEATER-A/C VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8974 Air Door Actuator / Motor: Service and Repair Without Air Conditioning Mode Valve Vacuum Actuator Heater Module - Disassembled View (1 Of 2) The vacuum actuators are located under the instrument panel and attached to the HVAC module. Remove or Disconnect 1. Negative battery cable. 2. Left sound insulator 3. I/P trim pad. 4. Air distribution duct. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8975 5. Actuator and actuator rod from module. 6. Vacuum hoses from actuator. 7. Vacuum actuator from the vehicle. Install or Connect 1. Vacuum actuator from below. 2. Vacuum hoses to actuator. 3. Actuator rod to module (from above). 4. Air distribution duct. 5. I/P trim pad. 6. Left sound insulator. 7. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8976 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Defrost Vacuum Actuator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8977 Heater Module - Disassembled View (1 Of 2) The vacuum actuators are located under the instrument panel and attached to the HVAC module. Remove or Disconnect 1. Negative battery cable. 2. I/P trim pad. 3. Passenger side SIR module. 4. Vacuum hose from actuator. 5. Clip attaching actuator to the module. 6. Actuator arm from the valve. 7. Actuator from the vehicle. Install or Connect 1. Actuator arm to the valve. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8978 2. Actuator to the module, snap into place. 3. Vacuum hose to the actuator. 4. Passenger side SIR module. 5. I/P trim pad. 6. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > With Air Conditioning > Page 8979 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair Air Door Cable: Service and Repair The temperature control cable is attached to the right of the HVAC module heater case. Remove or Disconnect 1. Right sound insulator panel. 2. Cable from module. 3. I/P trim plate. 4. Heater and A/C control and pull rearward. 5. Cable from heater and A/C control Install or Connect 1. Cable to heater and A/C control. 2. Heater and A/C control to I/P 3. I/P Trim plate. 4. Cable to module. 5. Right sound insulator panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Air Distribution Ducts and Outlets Air Duct: Specifications Air Distribution Ducts and Outlets Air Distribution Duct Screws ................................................................................................................ ..................................................... 2 N.m (18 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Air Distribution Ducts and Outlets > Page 8987 Air Duct: Specifications Rear Floor Air Duct or Outlet Floor Air Outlet Stud ............................................................................................................................ ...................................................... 7 N.m (62 lb. in.) Rear Floor Outlet Screws .................................................................................................................... ....................................................... 6 N.m (53 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Air Distribution Ducts and Outlets > Page 8988 Air Duct: Specifications Air Inlet Assembly Air Inlet Assembly Screws ................................................................................................................... ...................................................... 2 N.m (18 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 8989 Rear Floor Air Outlet Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets Air Duct: Service and Repair Air Distribution Ducts and Outlets It is necessary to partially remove portions of the I/P assembly to gain access to the air distribution ducts as required. Remove or Disconnect 1. Negative battery cable. 2. I/P trim. 3. Air distribution duct. Install or Connect 1. Air distribution duct. 2. I/P trim. 3. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets > Page 8992 Air Duct: Service and Repair Rear Floor Air Duct or Outlet Rear Floor Air Outlet The rear floor outlet duct is located under the console and floor carpeting. Remove or Disconnect 1. Console. 2. Floor carpeting partially removed to rear of front seat. 3. Rear floor duct or outlet. Install or Connect 1. Rear floor duct or outlet. 2. Floor carpeting. 3. Console. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets > Page 8993 Air Duct: Service and Repair Air Outlets and Side Window Defogger Outlets Description Remove or Disconnect 1. Gently pry out with blunt tool. 2. Air outlet. Install or Connect 1. Align outlet and carefully press into place. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets > Page 8994 Air Duct: Service and Repair Air Distribution Ducts Left Side Air Distribution Duct I/P Air Distribution Duct Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets > Page 8995 I/P Left Air Distribution Duct Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets > Page 8996 I/P Left And Right Defogger Ducts Remove or Disconnect 1. I/P cluster trim plate. 2. I/P assembly from tie bar. 3. Left side air distribution duct. Install or Connect 1. Left side air distribution duct onto I/P. 2. I/P assembly. 3. I/P cluster trim pad. Right Side Air Distribution Duct I/P Air Distribution Duct Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets > Page 8997 I/P Left Air Distribution Duct Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Ducts and Outlets > Page 8998 I/P Left And Right Defogger Ducts Remove or Disconnect 1. I/P cluster trim plate. 2. Right side air distribution duct. Install or Connect 1. Right side air distribution duct onto I/P. 2. I/P cluster trim pad. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair Air Register: Service and Repair Description Remove or Disconnect 1. Screw to grille. 2. Grille from I/P. Install or Connect 1. Grille to I/P. 2. Screw to grille. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Blower Motor and Fan Blower Motor: Locations Blower Motor and Fan Heater Module - Disassembled View (1 Of 2) The blower motor and fan are located in the lower right corner of the HVAC module. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Blower Motor and Fan > Page 9006 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Blower Motor and Fan > Page 9007 HVAC Assembly Under I/P Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Specifications Blower Motor: Service and Repair Specifications Blower Motor Screws ........................................................................................................................... ...................................................... 5 N.m (44 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Specifications > Page 9010 Blower Motor: Service and Repair Blower Motor and Fan Assembly Heater Module - Disassembled View (1 Of 2) The blower motor and fan are located in the lower right corner of the HVAC module. The blower motor and fan are serviced as an assembly only. Remove or Disconnect 1. Negative battery cable. 2. Right sound insulator. 3. Electrical connections at blower motor. 4. Blower motor retaining screws. 5. Blower motor and fan assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Specifications > Page 9011 Install or Connect 1. Blower motor and fan assembly. 2. Retaining screws. 3. Electrical connections. 4. Right sound insulator. 5. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Specifications > Page 9012 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Blower Motor Resistor Screws ............................................................................................................ ......................................................... 1 N.m (9 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 9016 Blower Motor Resistor: Locations BLOWER MOTOR RESISTOR Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 9017 Component Location Views The blower motor resistor is located in the lower right corner of the HVAC module, between the blower motor and the front of dash. IMAGE KEY 1. VALVE HOUSING COVER 2. HEATER/BLOWER MODULE BOLT 3. DEFROSTER VALVE 4. MODE VALVE 5. HEATER-VACUUM TANK 6. HEATER MODULE MOUNTING BRACKET 7. HEATER-CONTROL 8. HEATER VALVE LEVER LINK 9. DEFROSTER VALVE ACTUATOR 10. HEATER CASE 11. HEATER VALVE 12. MODE VALVE ACTUATOR 13. TEMPERATURE VALVE CLIP 14. TEMPERATURE VALVE 15. HEATER CORE SHROUD 16. HEATER CORE 17. HEATER CORE STRAP 18. HEATER COVER 19. HEATER OUTLET 20. HEATER CORE SHROUD SEAL 21. HEATER CORE TUBE AND MOUNT SEAL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 9018 22. HEATER CORE SEAL 23. HEATER AND A/C CONTROL SWITCH HARNESS 24. DEFROSTER DUCT 25. BLOWER MOTOR BOLTS 26. BLOWER MOTOR ISOLATOR 27. BLOWER MOTOR 28. BLOWER FAN 29. BLOWER RESISTOR 30. HEATER CASE SEAL 31. BLOWER AND AIR INLET CASE 32. MOUNTING SEAL 33. AIR INLET HOUSING 34. VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 9019 Blower Motor Resistor: Service and Repair Heater Module - Disassembled View (1 Of 2) The blower motor resistor is located in the lower right corner of the HVAC module, between the blower motor and the front of dash. Remove or Disconnect 1. Negative battery cable. 2. Right sound insulator. 3. Blower motor. 4. Cut portion of dash mat to gain access to the rear resistor screw. 5. Electrical connections at blower resistor. 6. Blower resistor screws and resistor. Install or Connect Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 9020 1. Blower resistor and resistor screws. 2. Replace portion of dash mat cut in removal procedure. 3. Electrical connections at blower resistor. 4. Blower motor. 5. Right sound insulator. 6. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 9021 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair Remove or Disconnect 1. Negative battery cable. 2. I/P trim plate. 3. Control assembly screws and pull control assembly away from the I/P. 4. Blower switch knob. 5. Electrical connection. 6. Blower switch retaining screws and blower switch. Install or Connect 1. Blower switch and retaining screws. 2. Electrical connection. 3. Blower switch knob. 4. Control assembly and retaining screws. 5. I/P trim plate. 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Torque Values Compressor Clutch: Specifications Torque Values Shaft nut .............................................................................................................................................. .................................................. 16.5 N.m (12 lbs.ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Torque Values > Page 9030 Compressor Clutch: Specifications Compressor Clutch Air Gap Between clutch plate and rotor ................................................................................................................................................ 0.40-0.50mm (0.015-0.020") Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9031 Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Conventional Mounted Compressor Clutch: Service and Repair Conventional Mounted Removing Shaft Nut Clutch Plate And Hub Assembly Removal Remove or Disconnect 1. Clamp the holding fixture J 34992 in a vise and attach compressor to holding fixture with thumb screws J 34992-1. 2. Keep the clutch hub and drive plate assembly from turning by using the clutch hub holding tool J 33027-A. Remove the shaft nut using shaft nut socket J 33022. 3. Thread the Clutch Plate and Hub Assembly Remover J 33013-B into the hub. Hold the body of the remover with a wrench and turn the center screw into the remover body to remove the clutch plate and hub assembly. 4. Remove the shaft key and retain for reassembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Conventional Mounted > Page 9034 Shaft Key, Clutch Plate/Hub Installation Installing Clutch Plate & Hub Assembly Install or Connect 1. Install the shaft key into the hub key groove. Allow the key to project approximately 3.2 mm (1/8") out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove. 2. Be sure the frictional surface of the clutch plate and the clutch rotor are clean before installing the clutch plate and hub assembly. 3. Align the shaft key with the shaft keyway and place the clutch plate and the hub assembly onto the compressor shaft. NOTICE: Do not drive or pound on the clutch hub or shaft. Internal damage to compressor may result. 4. Remove the J 33013-B remover-installer center screw and reverse the body direction on the center screw as shown in the illustration. 5. Install the clutch plate and hub installer J 33013-B with bearing as shown in the illustration. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Conventional Mounted > Page 9035 The body of the J 33013-B installer should be backed off sufficiently to allow the center screw to be threaded onto the end of the compressor shaft. 6. Hold the center screw with a wrench. Tighten the hex portion of the installer J 33013-B body to press the hub onto the shaft. Tighten the body several turns, remove the installer and check to see that the shaft key is still in place in the keyway before installing the clutch plate and hub assembly to its final position. The air gap between frictional surfaces of the clutch plate and clutch rotor should be 0.40-0.50mm (0.015-0.020"). ^ If the center screw is threaded fully onto the end of the compressor shaft, or if the body of the installer is held and the center screw is rotated, the key will assume the position as shown in the illustration and will break the clutch hub. 7. Remove installer J 33013-B, check for proper positioning of the shaft key (even or slightly above the clutch hub). Install the shaft nut. Hold the clutch plate and hub assembly with clutch hub holding tool J 33027-A and using shaft nut socket J 33022, tighten the nut against the crankshaft shoulder to 16.5 N.m (12 lbs.ft.) torque, using a torque wrench. 8. Spin the pulley rotor by hand to see that the rotor is not rubbing the clutch drive plate. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Conventional Mounted > Page 9036 Compressor Clutch: Service and Repair Direct Mounted Removing Shaft Nut Clutch Plate And Hub Assembly Removal Remove or Disconnect 1. Clamp the holding fixture J 41790 in a vise and attach compressor to holding fixture with nuts and bolts (2). 2. Keep the clutch hub and drive plate assembly from turning by using the clutch hub holding tool J 33027-A. Remove the shaft nut using shaft nut socket J 33022. 3. Thread the Clutch Plate and Hub Assembly Remover J 33013-B into the hub. Hold the body of the remover with a wrench and turn the center screw into the remover body to remove the clutch plate and hub assembly. 4. Remove the shaft key and retain for reassembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Conventional Mounted > Page 9037 Shaft Key, Clutch Plate/Hub Installation Installing Clutch Plate & Hub Assembly Install or Connect 1. Install the shaft key into the hub key groove. Allow the key to project approximately 3.2 mm (1/8") out of the keyway. The shaft key is curved slightly to provide an interference fit in the hub key groove. 2. Be sure the frictional surface of the clutch plate and the clutch rotor are clean before installing the clutch plate and hub assembly. 3. Align the shaft key with the shaft keyway and place the clutch plate and the hub assembly onto the compressor shaft. NOTICE: Do not drive or pound on the clutch hub or shaft. Internal damage to compressor may result. 4. Remove the J 33013-B remover-installer center screw and reverse the body direction on the center screw as shown in the illustration. 5. Install the clutch plate and hub installer J 33013-B with bearing as shown in the illustration. The body of the J 33013-B installer should be backed off sufficiently to allow the center screw to be threaded onto the end of the compressor shaft. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Conventional Mounted > Page 9038 6. Hold the center screw with a wrench. Tighten the hex portion of the installer J 33013-B body to press the hub onto the shaft. Tighten the body several turns, remove the installer and check to see that the shaft key is still in place in the keyway before installing the clutch plate and hub assembly to its final position. The air gap between frictional surfaces of the clutch plate and clutch rotor should be 0.40-0.50mm (0.015-0.020"). ^ If the center screw is threaded fully onto the end of the compressor shaft, or if the body of the installer is held and the center screw is rotated, the key will assume the position as shown in the illustration and will break the clutch hub. 7. Remove installer J 33013-B, check for proper positioning of the shaft key (even or slightly above the clutch hub). Install the shaft nut. Hold the clutch plate and hub assembly with clutch hub holding tool J 33027-A and using shaft nut socket J 33022, tighten the nut against the crankshaft shoulder to 16.5 N.m (12 lbs.ft.) torque, using a torque wrench. 8. Spin the pulley rotor by hand to see that the rotor Is not rubbing the clutch drive plate. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Locations Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted Compressor Clutch Bearing: Service and Repair Conventional Mounted Remove Removing Pulley Rotor & Bearing Assembly Retaining Ring Installing Pulley Rotor/Bearing Puller Guide Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9044 Removing Pulley Rotor And Bearing Assembly Pulley Rotor Bearing Removal Remove or Disconnect 1. Remove the clutch plate and hub assembly as described previously. 2. Remove rotor and bearing assembly retaining ring, using snap ring pliers J 6083. 3. Install pulley rotor and bearing puller guide J 33023-A to the front head and install J 33020 pulley rotor and bearing puller down into the inner circle of slots in the rotor. Turn the J 33020 puller clockwise in the slots to engage the puller tangs with the segments between the slots in the rotor. 4. Hold the J 33020 puller in place and tighten the puller screw against the puller guide to remove the pulley rotor and bearing assembly. 5. To prevent damage to the pulley rotor during bearing removal the rotor hub must be properly supported. Remove the forcing screw from J 33020 puller and, with the puller tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks as shown in the illustration. 6. Drive the bearing out of the rotor hub with rotor bearing remover J 9398-A and J 29886 universal handle. NOTICE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9045 Replace Installing Pulley Rotor Bearing Staking Bearing In Rotor Hub Bore Bearing Staked In Place Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9046 Installing Pulley Rotor And Bearing Assembly Removing Pulley Rotor & Bearing Assembly Retaining Ring Install or Connect 1. Place the pulley rotor on the J 21352-A support block to fully support the rotor hub during bearing installation. NOTICE: Do Not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 2. Align the new bearing squarely with the hub bore and using puller and bearing installer J 9481-A with universal handle J 29886, drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing if used as shown. 3. Place bearing staking guide J 33019-1 and bearing staking pin J 33019 in the hub bore as shown in the illustration. Shift the rotor and bearing assembly on the J 21352-A support block to give full support of the hub under the staking pin location. A heavy-duty rubber band may be used to hold the stake pin in the guide, and the stake pin should be properly positioned in the guide after each impact on the pin. 4. Using care to prevent personal injury, strike the staking pin with a hammer until a metal stake, similar to the original, is formed down to but not touching the bearing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9047 The stake metal should not contact the outer face of the bearing to prevent the possibility of distorting the outer race. Stake three (3) places 120° apart as shown in the illustration. 5. With the compressor mounted to the J 34992 holding fixture, position the rotor and bearing assembly on the front head. 6. Position the J 33017 pulley rotor and bearing installer and J 33023-A puller pilot directly over the inner race of the bearing. 7. Position puller crossbar J 8433-1 on the puller pilot J 33023-A and assemble the two J 34992-2 through bolts and washers through the puller bar slots and thread them into the J 34992 holding fixture. The thread of the through bolts should engage the full thickness of the holding fixture. 8. Tighten the center screw in the J 8433-1 puller crossbar to force the pulley rotor and bearing assembly onto the compressor front head. Should the J 33017 pulley rotor and bearing installer slip off direct in-line contact with the inner face of the bearing, loosen the J 8433-3 center forcing screw and realign the installer and pilot so that the J 33017 installer will properly clear the front head. 9. Install rotor and bearing assembly retainer ring, using snap ring pliers J 6083. 10. Reinstall clutch plate and hub assembly as described previously. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9048 Compressor Clutch Bearing: Service and Repair Direct Mounted Remove Removing Pulley & Bearing Assembly Retaining Ring Installing Pulley Rotor/Bearing Puller Guide Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9049 Removing Pulley And Bearing Assembly Pulley Rotor Bearing Removal Remove or Disconnect 1. Remove the clutch plate and hub assembly as described previously. 2. Remove rotor and bearing assembly retaining ring, using snap ring pliers J 6083. 3. Install pulley rotor and bearing puller guide J 33023-A to the front head and install J 33020 pulley rotor and bearing puller down into the inner circle of slots in the rotor. Turn the J 33020 puller clockwise in the slots to engage the puller tangs with the segments between the slots in the rotor. 4. Hold the J 33020 puller in place and tighten the puller screw against the puller guide to remove the pulley rotor and bearing assembly. 5. To prevent damage to the pulley rotor during bearing removal the rotor hub must be properly supported. Remove the forcing screw from J 33020 puller and, with the puller tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks as shown in the illustration. 6. Drive the bearing out of the rotor hub with rotor bearing remover J 9398-A and J 29886 universal handle. NOTICE: It is not necessary to remove the staking in front of the bearing to remove the bearing. however, it will be necessary to file away the old Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9050 stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. Replace Installing Pulley Rotor Bearing Staking Bearing In Rotor Hub Bore Bearing Staked In Place Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9051 Installing Pulley Rotor And Bearing Assembly Removing Pulley & Bearing Assembly Retaining Ring Install or Connect 1. Place the pulley rotor on the J 21352-A support block to fully support the rotor hub during bearing installation. NOTICE: Do Not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 2. Align the new bearing squarely with the hub bore and using puller and bearing installer J 9481-A with universal handle J 29886, drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing if used as shown. 3. Place bearing staking guide J 33019-1 and bearing staking pin J 33019 in the hub bore as shown in the illustration. Shift the rotor and bearing assembly on the J 21352-A support block to give full support of the hub under the staking pin location. A heavy-duty rubber band may be used to hold the stake pin in the guide, and the stake pin should be properly positioned in the guide after each impact on the pin. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Conventional Mounted > Page 9052 4. Using care to prevent personal injury. strike the staking pin with a hammer until a metal stake, similar to the original, is formed down to but not touching the bearing. The stake metal should not contact the outer face of the bearing to prevent the possibility of distorting the outer race. Stake three (3) places 120° apart as shown in the illustration. 5. With the compressor mounted to the J 34992 holding fixture, position the rotor and bearing assembly on the front head. 6. Position the J 33017 pulley rotor and bearing installer and J 33023-A puller pilot directly over the inner race of the bearing. 7. Position puller crossbar J 8433-1 on the puller pilot J 33023-A and assemble the two through bolts and washers through the puller bar slots and thread them into the J 33025 puller leg. The thread of the through bolts should engage the full thickness of the puller legs. The two puller legs require two different bolt lengths. 8. Tighten the center screw in the J 8433-1 puller crossbar to force the pulley rotor and bearing assembly onto the compressor front head. Should the J 33017 pulley rotor and bearing installer slip off direct in-line contact with the inner face of the bearing, loosen the J 8433-3 center forcing screw and realign the installer and pilot so that the J 33017 installer will properly clear the front head. 9. Install rotor and bearing assembly retainer ring, using snap ring pliers J 6083. 10. Reinstall clutch plate and hub assembly as described previously. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Conventional Mounted Compressor Clutch Coil: Service and Repair Conventional Mounted Clutch Coil Assembly Removal Installing Clutch Coil Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Conventional Mounted > Page 9058 Staking Clutch To Front Head Details Of Stakes In Front Head For Clutch Coil Remove or Disconnect 1. Perform Steps 1 through 4 of "Clutch Rotor and/or Bearings" removal procedure. Mark clutch coil terminal location on compressor front head. 2. Install J 33023-A puller pilot on front head of compressor. Also install J 8433-1 puller crossbar with J 33025 puller legs as shown in the illustration. 3. Tighten J 8433-3 forcing screw against the puller pilot to remove the clutch coil. Install or Connect 1. Place the clutch coil assembly on the front head with the terminals positioned at the "marked" location. 2. Place the J 33024 clutch coil installer over the internal opening of the clutch coil housing and align installer with the compressor front head. 3. Center the J 8433-1 puller crossbar in the countersunk center hole of the J 33024 clutch coil installer. Install the J34992-2 through bolts and washers through the crossbar slots and thread them, into the holding fixture J 34992 to full fixture thickness. 4. Turn the center forcing screw of the J 8433-1 puller crossbar to force the clutch coil onto the front head. Be sure clutch coil and J 33024 installer stay "in-line" during installation. 5. When coil is fully seated on the front head, use a 1/8" diameter drift punch and stake the front head at three (3) places 120° apart, to ensure clutch coil remaining in position. ^ Stake size should be only one half the area of the punch tip and only approximately 0.28-035mm (0.010-0.015") deep. 6. Install rotor and bearing assembly and the clutch plate and hub assembly according as described previously. 7. Install shaft nut. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Conventional Mounted > Page 9059 Compressor Clutch Coil: Service and Repair Direct Mounted Clutch Coil Assembly Removal Remove or Disconnect 1. Perform Steps 1 through 4 of Clutch Rotor and/or Bearings" removal procedure. Mark clutch coil terminal location on compressor front head. 2. Install J 33023-A puller pilot on front head of compressor. Also install J 8433-1 puller crossbar with J 33025 puller legs as shown in the illustration. 3. Tighten J 8433-3 forcing screw against the puller pilot to remove the clutch coil. Installing Clutch Coil Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Conventional Mounted > Page 9060 Staking Clutch Coil To Front Head Details Of Stakes In Front Head For Clutch Coil Install or Connect 1. Place the clutch coil assembly on the front head with the terminals positioned at the "marked" location. 2. Place the J 33024 clutch coil installer over the internal opening of the clutch coil housing and align installer with the compressor front head. 3. Center the J 8433-1 puller crossbar in the countersunk center hole of the J 33024 clutch coil installer. Install the J 34992-2 through bolts and washers through the crossbar slots and thread them, into the holding fixture J 34992 to full fixture thickness. 4. Turn the center forcing screw of the J 8433-1 puller crossbar to force the clutch coil onto the front head. Be sure clutch coil and J 33024 installer stay "in-line" during installation. 5. When coil is fully seated on the front head, use a 1/8" diameter drift punch and stake the front head at three (3) places 120° apart, to ensure clutch coil remaining in position. ^ Stake size should be only one half the area of the punch tip and only approximately 0.280-0.35mm (0.010-0.015") deep. 6. Install rotor and bearing assembly and the clutch plate and hub assembly according as described previously. 7. Install shaft nut. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Locations Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Locations > Page 9064 Compressor Control Valve Assembly: Service and Repair V-5 Compressor Tools Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station J 5403 Internal Snap Ring Pliers. Remove or Disconnect 1. Negative battery cable 2. Recover refrigerant 3. Raise vehicle. 4. Control valve retaining ring using J 5403. 5. Control valve. Install or Connect 1. Control valve. 2. Control valve retaining ring using J 5403. 3. Raise vehicle. 4. Evacuate and recharge refrigerant system. 5. Negative battery cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > A/C Compressor Seal Washer - Reference Chart Compressor Shaft Seal: Technical Service Bulletins A/C Compressor Seal Washer - Reference Chart File In Section: 1 - HVAC Bulletin No.: 63-12-15 Date: November, 1996 INFORMATION Subject: Reference Chart for A/C Compressor Seal Washers Models: 1997 and Prior Passenger Cars (Except Corvette and GEO) 1997 and Prior Light Duty Trucks (Except Tracker) GMSPO A/C compressors include a seal washer kit. These kits contain various color edge painted washer seals and inserts in which only two (2) washers and possibly one (1) insert are used. It has come to our attention that some packaging discrepancies were found and some of the seals cannot be properly identified for installation. These seals are very close in size and some of the seals were inadvertently edge painted the wrong color or not painted. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > A/C Compressor Seal Washer - Reference Chart > Page 9069 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > A/C Compressor Seal Washer - Reference Chart > Page 9070 The chart shown will help to properly identify the seals. Use the chart by placing the seal over the pictured seal to identity inside and outside diameters and thickness. Because these seals are very similar in size, specifications are also listed in the chart. Important: If seals are damaged upon installation, obtain new seal kit. Seals will be available separately at a later date. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Page 9071 Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted Compressor Shaft Seal: Service and Repair Conventional Mounted Seal Leak Detection A shaft seal should not be changed because of small amounts of oil found on an adjacent surface. The seal is designed to leak some oil for lubrication purposes. A shaft seal should be changed only when a large amount of sprayed oil is found, and only after actual refrigerant leakage is found by using an approved leak detector, J 39400 or equivalent. Removing Or Installing Shaft Seal Retaining Ring Removing Shaft Seal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted > Page 9074 Removing Shaft Seal O-Ring Compressor Shaft Seal Remove or Disconnect 1. Recover refrigerant using J 39500-GM. 2. Loosen and reposition compressor in mounting brackets. 3. Remove clutch plate and hub assembly from compressor as described in minor repairs. 4. Remove the shaft seal retainer ring, using snap ring pliers J 5403. 5. Thoroughly clean inside of compressor neck area surrounding the shaft. tile exposed portion of the seal. the shaft itself and O-ring groove. Any dirt or foreign material getting into compressor may cause damage. 6. Fully engage the knurled tangs of seal remover-installer J2312-A into the recessed portion of the seal by turning the handle clockwise. Remove the seal from the compressor with a rotary-pulling motion. Discard the seal. The handle should be hand-tightened securely. Do not use a wrench or pliers. 7. Remove and discard the seal O-ring from the compressor neck using O-ring remover J 9553-01. 8. Recheck the shaft and inside of the compressor neck for dirt or foreign material and be sure these areas are perfectly clean before installing new parts. Clean 1. Thoroughly clean seal O-ring groove in front head. NOTICE: Seals should not be re-used. Always use a new specification service seal kit. Be sure that the seal to be installed is not scratched or damaged in any way. Make sure that the seal is free of lint and dirt that could damage the seal surface or prevent sealing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted > Page 9075 Installing Shaft Seal O-Ring Lip Seal Installed On Seal Protector Removing Or Installing Shaft Seal Retaining Ring Install or Connect 1. Dip the new seal O-ring in clean 525 viscosity refrigerant oil and assemble onto O-ring installer J 33011. "New". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted > Page 9076 2. Insert the O-ring installer J 33011 into the compressor neck until the installer "bottoms." Lower the moveable slide of the O-ring installer to release the O-ring into the seal O-ring lower groove. (The compressor neck top groove is for the shaft seal retainer ring.) Rotate the installer to seat the O-ring and remove the installer. 3. Dip the new seal in clean 525 viscosity refrigerant oil and assemble seal to Seal Installer J 23128-A, by turning handle clockwise. The stamped steel case side of the lip seal must be engaged with knurled tangs of installer so that flared-out side of lip seal is facing and installed towards the compressor. Install shaft seal protector J 34614 on the lip seal. Place the seal protector J 34614 over end of compressor shaft, and slide the new seal onto the shaft with a rotary motion until it stops. Take care not to dislodge the O-ring. Be sure the seal makes good contact with the O-ring. Disengage the installer from the seal and remove the installer J 23128-A and the shaft seal protector J 34614. NOTICE: Handling and care of seal protector is important. If seal protector is nicked or the bottom flared. the new seal may be damaged during installation. 4. Install the new seal retainer ring with its flat side against the seal, using snap-ring pliers J 5403. Use the sleeve from O-ring installer J 33011 to press in on the seal retainer ring so that it snaps into its groove. 5. To leak test. install compressor leak test fixture J 39893 on rear head of compressor and connect gage charging lines using J 39500-GM Refrigerant Recovery System or equivalent. Pressurize suction and high-side of compressor with R134a Refrigerant. Temporarily install the shaft nut and, with the compressor in horizontal position. rotate the compressor shaft in normal direction of rotation several turns by hand. Leak test the seal area and correct any leak found. Recover refrigerant. Remove shaft nut. 6. Remove any excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck. 7. Install the clutch plate and hub assembly as described in minor repair procedures. 8. Reinstall the compressor, belt and tighten bracket. 9. Evacuate and charge the refrigerant system using J 39500-GM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted > Page 9077 Compressor Shaft Seal: Service and Repair Direct Mounted Seal Leak Detection A shaft seal should not be changed because of small amounts of oil found on an adjacent surface. The seal is designed to leak some oil for lubrication purposes. A shaft seal should be changed only when a large amount of sprayed oil is found, and only after actual refrigerant leakage is found by using an approved leak detector. J 39400 or equivalent. Removing Or Installing Shaft Seal Retaining Ring Removing Shaft Seal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted > Page 9078 Removing Shaft Seal O-Ring Remove or Disconnect 1. Recover refrigerant using J 39500-GM. 2. Loosen and reposition compressor in mounting brackets. 3. Remove clutch plate and hub assembly from compressor as described in minor repairs. 4. Remove the shaft seal retainer ring, using snap ring pliers J 5403. 5. Thoroughly clean inside of compressor neck area surrounding the shaft. the exposed portion of the seal, the shaft itself and O-ring groove. Any dirt or foreign material getting into compressor may cause damage. 6. Fully engage the knurled tangs of seal remover-installer J 23128-A into the recessed portion of the seal by turning the handle clockwise. Remove the seal from the compressor with a rotary-pulling motion. Discard the seal. The handle should be hand-tightened securely. Do not use a wrench or pliers. 7. Remove and discard the seal O-ring from the compressor neck using O-ring remover J 955301. 8. Recheck the shaft and inside of the compressor neck for dirt or foreign material and be sure these areas are perfectly clean before installing new parts. Compressor Shaft Seal Clean 1. Thoroughly clean seal O-ring groove in front head. NOTICE: Seals should not be re-used. Always use a new specification service seal kit. Be sure that the seal to be installed is not scratched or damaged in any way. Make sure that the seal is free of lint and dirt that could damage the seal surface or prevent sealing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted > Page 9079 Installing Shaft Seal O-Ring Lip Seal Installed On Seal Protector Removing Or Installing Shaft Seal Retaining Ring Install or Connect 1. Dip the new seal O-ring in clean 525 viscosity refrigerant oil and assemble onto O-ring installer 33011. "New". 2. Insert the O-ring installer J 33011 into the compressor neck until the installer "bottoms." Lower the moveable slide of the O-ring installer to Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Conventional Mounted > Page 9080 release the O-ring into the seal O-ring lower groove. (The compressor neck top groove is for the shaft seal retainer ring.) Rotate the installer to seat the O-ring and remove the installer. 3. Dip the new seal in clean 525 viscosity refrigerant oil and assemble seal to Seal Installer J 23128-A, by turning handle clockwise. The stamped steel case side of the lip seal must be engaged with knurled tangs of installer so that flared-out side of lip seal is facing and installed towards the compressor. In stall shaft seal protector J 34614 on the lip seal. Place the seal protector J 34614 over end of compressor shaft, and slide the new seal onto the shaft with a rotary motion until it stops. Take care not to dislodge the O-ring. Be sure the seal makes good contact with the O-ring. Disengage the installer from the seal and remove the installer J 23128-A and the shaft seal protector J 34614. NOTICE: Handling and care of seal protector is important. If seal protector is nicked or the bottom flared, the new seal may be damaged during installation. 4. Install the new seal retainer ring with its flat side against the seal, using snap-ring pliers J 5403. Use the sleeve from O-ring installer J 33011 to press In on the seal retainer ring so that it snaps into its groove. 5. To leak test, install compressor leak test fixture J 39893 on rear head of compressor and connect gage charging lines using J 39500-GM Refrigerant Recovery System or equivalent. Pressurize suction and high-side of compressor with R-134a Refrigerant. Temporarily install the shaft nut and, with the compressor in horizontal position. rotate the compressor shaft in normal direction of rotation several turns by hand. Leak test the seal area and correct any leak found. Recover refrigerant. Remove shaft nut. 6. Remove any excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck. 7. Install the clutch plate and hub assembly as described in minor repair procedures. 8. Reinstall the compressor, belt and tighten bracket. 9. Evacuate and charge the refrigerant system using J 39500-GM. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Locations RH Front Of Engine And Cooling Fan Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications Condenser Inlet Fitting, nut ................................................................................................................. ...................................................... 16 N.m (12 lb. ft.) Condenser Outlet Fitting nut ................................................................................................................ ..................................................... 16 N.m (12 lb. ft.) Condenser to Radiator Screws ............................................................................................................ ........................................................ 6 N.m (53 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9087 Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9088 Condenser HVAC: Description and Operation The condenser in front of the radiator is made up of coils which carry the refrigerant. Cooling fins provide rapid transfer of heat. Air passing through the condenser cools the high-pressure, high-temperature refrigerant vapor, causing it to condense into a liquid. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9089 Condenser HVAC: Service and Repair Condenser Mounting Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Negative battery cable. 2. Recover refrigerant. 3. Upper closeout panel. 4. Hood latch from mounting plate. 5. Right and left headlamp assemblies. 6. Raise vehicle. 7. Disconnect forward SIR sensor harness. 8. Lower vehicle. 9. Right radiator mount. 10. Hood latch support bracket & forward sensor w/harness. 11. Compressor and accumulator hose assemblies from the condenser, discard O-rings. Important ^ Use back-up wrench to prevent twisting of block fitting. 12. Condenser. Install or Connect 1. Condenser in vehicle. 2. Compressor and accumulator hose assemblies to condenser, using new O-rings. Important ^ Use back-up wrench to prevent twisting of block fitting. 3. Hood latch support bracket & forward sensor w/harness. 4. Right radiator mount. 5. Raise vehicle. 6. Connect forward SIR sensor harness. 7. Lower vehicle. 8. Right and left headlamp assemblies. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9090 9. Hood latch assembly and adjust. 10. Upper closeout panel. 11. Recharge A/C system. 12. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Heater Control Assembly Control Assembly: Locations Heater Control Assembly Heater Control Mounting - Chevrolet Heater Control Mounting - Pontiac Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Heater Control Assembly > Page 9095 Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Heater Control Assembly > Page 9096 HVAC Assembly Under I/P Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > C1 Control Assembly: Diagrams C1 Heater - A/C And Rear Defogger Control Assembly: C1 Heater - A/C And Rear Defogger Control Assembly: C1 Heater - A/C And Rear Defogger Control Assembly: C1 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > C1 > Page 9099 Heater - A/C And Rear Defogger Control Assembly: C1 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > C1 > Page 9100 Control Assembly: Diagrams C2 Heater - A/C And Rear Defogger Control Assembly: C2 Heater - A/C And Rear Defogger Control Assembly: C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > C1 > Page 9101 Control Assembly: Diagrams C3 Heater - A/C And Rear Defogger Control Assembly: C3 Heater - A/C And Rear Defogger Control Assembly: C3 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 9102 Control Assembly: Service and Repair Heater Control Mounting - Chevrolet Heater Control Mounting - Pontiac Remove or Disconnect 1. Negative battery cable. 2. I/P trim plate. 3. Heater and A/C control retaining screws and pull heater and A/C control away from the instrument panel. 4. Electrical and vacuum connections. 5. Temperature control cable from heater and A/C control. Install or Connect 1. Temperature control cable to heater and A/C control. 2. Electrical and vacuum connections. 3. Heater and A/C control and retaining screws to instrument panel. 4. I/P trim plate. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 9103 5. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9112 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9113 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9119 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 9120 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Evaporator Evaporator Core: Specifications Evaporator Evaporator Clamp Screw ..................................................................................................................... ......................................................... 1 N.m (9 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Evaporator > Page 9123 Evaporator Core: Specifications Evaporator Tube (Evaporator to Condenser) Evaporator Tube at Evaporator ........................................................................................................... ...................................................... 24 N.m (18 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Evaporator Core Evaporator Core: Locations Evaporator Core HVAC Module - Disassemble View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Evaporator Core > Page 9126 HVAC Module Cut Away View Image Key 1 VALVE HOUSING COVER 2 HEATER-A/C MODULE BOLTS 3 DEFROSTER VALVE 4 MODE VALVE 5 VACUUM TANK 6 HVAC MODULE BRACKET 7 HEATER-A/C CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HVAC CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Evaporator Core > Page 9127 18 HEATER CORE COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 A/C EVAPORATOR TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER-A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLT 26 BLOWER MOTOR BOLT INSULATOR 27 BLOWER MOTOR 28 BLOWER MOTOR FAN 29 BLOWER RESISTOR 30 A/C EVAPORATOR WATER FILTER RETAINER 31 A/C EVAPORATOR WATER FILTER 32 EVAPORATOR CORE MATING SPACER 33 EVAPORATOR CORE 34 EVAPORATOR CORE SEAL 35 A/C EVAPORATOR BRACKET 36 BLOWER AND AIR INLET CASE 37 MOUNT SEAL 38 AIR INLET HOUSING 39 AIR INLET VALVE ACTUATOR 40 HEATER-A/C VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Evaporator Core > Page 9128 Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 9129 Evaporator Core: Description and Operation The evaporator is a device which cools and dehumidifies the air before it enters the passenger compartment. High-pressure liquid refrigerant flows through the expansion tube, becomes a low-pressure liquid, and then enters the evaporator. The heat in the air passing through the evaporator core is transferred to the cooler surface of the core, thereby cooling the air. As the process of heat transfer from the air to the evaporator core surface is taking place, any moisture (humidity) in the air condenses on the outside surface of the evaporator core and is drained off as water. The evaporator is located inside the HVAC module at the front of dash. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Evaporator Core: Service and Repair Evaporator HVAC Module - Disassemble View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator > Page 9132 HVAC Module Cut Away View Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Negative battery cable. 2. Recover refrigerant. 3. Drain cooling system. 4. Raise vehicle. 5. Heater hoses from heater core. 6. Evaporator fittings from the evaporator and discard O-ring seals. 7. Moisture drain tube from module. 8. Lower vehicle. 9. I/P and console. 10. Heater outlet case and heater core cover. ^ There is a mounting screw located in a recess in the center of the cover 11. Heater core mounting clamps and heater core. 12. Heater core shroud and evaporator core. ^ There is a mounting screw located at the middle of the front of dash. Install or Connect 1. Evaporator. ^ See "Refrigerant Oil Distribution" if installing a new evaporator. 2. Heater core shroud, heater core and heater core mounting clamp. 3. Heater core case and heater outlet case. 4. I/P and console. 5. Raise vehicle. 6. Moisture drain tube to the heater - A/C module. 7. Evaporator fittings to evaporator using new O-ring seals lubricated in clean 525 viscosity refrigerant oil. 8. Heater hoses to heater core. 9. Lower vehicle. 10. Fill cooling system and check for leaks. 11. Evacuate and charge the A/C system. 12. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator > Page 9133 Image Key 1 VALVE HOUSING COVER 2 HEATER-A/C MODULE BOLTS 3 DEFROSTER VALVE 4 MODE VALVE 5 VACUUM TANK 6 HVAC MODULE BRACKET 7 HEATER-A/C CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HVAC CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER CORE COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 A/C EVAPORATOR TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER-A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLT 26 BLOWER MOTOR BOLT INSULATOR 27 BLOWER MOTOR 28 BLOWER MOTOR FAN 29 BLOWER RESISTOR 30 A/C EVAPORATOR WATER FILTER RETAINER 31 A/C EVAPORATOR WATER FILTER 32 EVAPORATOR CORE MATING SPACER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator > Page 9134 33 EVAPORATOR CORE 34 EVAPORATOR CORE SEAL 35 A/C EVAPORATOR BRACKET 36 BLOWER AND AIR INLET CASE 37 MOUNT SEAL 38 AIR INLET HOUSING 39 AIR INLET VALVE ACTUATOR 40 HEATER-A/C VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator > Page 9135 Evaporator Core: Service and Repair Evaporator Tube (Evaporator to Condenser) Evaporator Tube And Accumulator Tube Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Upper closeout panel. 3. Connection from the condenser and discard the O-ring seal. 4. Tube from retaining clip on the body side rail. 5. Raise vehicle. 6. Tube nut from the evaporator and discard the O-ring seats. 7. Lower the vehicle and remove the evaporator tube. Install or Connect 1. Set evaporator tube in place. 2. Raise vehicle. 3. The nut to evaporator using new O-ring seals. 4. Lower vehicle. 5. The to retaining clip on the body side rail. 6. Connection at condenser using new O-ring seals. 7. Upper closeout panel. 8. Evacuate and charge A/C system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator > Page 9136 Evaporator Core: Service and Repair Instrument Panel For Instrument Panel Service and Repair, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Locations HVAC Assembly Under I/P Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9143 Expansion Block/Orifice Tube: Description and Operation The expansion tube is a plastic assembly containing a fixed diameter tube with a mesh filter screen at either end. It is located at the condenser outlet tube. The fixed diameter tube creates a restriction to the high-pressure liquid refrigerant in the liquid line, metering the flow of refrigerant to the evaporator as a low-pressure liquid. When the engine is turned "OFF" with the A/C system operating, the refrigerant in the system will flow from the high-pressure side of the expansion tube (orifice) to the low-pressure side until the pressure is equalized. This may be detected as a faint sound of liquid flowing (hissing) for 30 to 60 seconds and is a normal condition. When system diagnostics indicate a restricted expansion tube, it may not be necessary to replace it. Metal chips, flakes or slivers found on the screen may be removed with compressed air and the expansion tube may be reused if: ^ The plastic frame is not broken. ^ The brass expansion tube is not damaged or plugged. ^ The screen material is not torn. ^ The screen is not plugged with fine gritty material. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 9144 Expansion Block/Orifice Tube: Service and Repair Evaporator Tube And Accumulator Tube The expansion tube is located at the condenser to evaporator line connection in the condenser. Important ^ Different designs and colors of orifice tubes may have been used in past production vehicles. When replacing an orifice tube, compare its design to the replacement part for correct orifice tube selection. The different styles of orifice tubes are not interchangeable. Tools Required: J 26549-E Expansion Tube Remover J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Upper closeout panel. 3. Connection at condenser. Discard O-ring seals. 4. Evaporator line from clip on body side rail. 5. Carefully remove the expansion tube with needle-nose pliers, or tool J 26549-E. In the event that difficulty is encountered during the removal of a restricted or plugged expansion tube (orifice tube), the following procedure is recommended: 1. Remove as much of any impacted residue as possible. 2. Carefully apply heat with heat gun (hair drier, epoxy drier or equivalent) approximately 7 mm (1/4 inch) from dimples on inlet pipe. Do not overheat pipe. 3. While applying heat, use expansion tube removal tools or J 26549-E to grip the expansion tube. Use a turning motion along with a push-pull motion to loosen and remove to the impacted expansion tube. Install or Connect 1. New expansion tube. 2. Evaporator line to clip. 3. Using new O-ring seals, assemble evaporator tube/condenser connection hand tight 4. Upper closeout panel. 5. Evacuate and charge the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 9149 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 9150 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9151 Heater Core: Specifications Heater Core Cover Screws .................................................................................................................. ......................................................... 1 N.m (9 lb. in.) Heater Core Shroud Screws ................................................................................................................ .......................................................... 1 N.m (9 lb. in.) Heater Core Strap Screws ................................................................................................................... .......................................................... 1 N.m (9 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9152 Heater Core: Locations Heater Module - Disassembled View (1 Of 2) Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9153 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9154 Heater Core: Service and Repair Heater Module - Disassembled View (1 Of 2) Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Raise vehicle. 4. Heater hoses from heater core. 5. Lower vehicle. 6. I/P. 7. Heater core outlet. 8. Heater core cover. ^ There is a mounting screw located in a recess in the center of the cover 9. Heater core mounting clamps and heater core. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9155 Install or Connect 1. Heater core and heater core mounting clamps. 2. Heater core cover. 3. Heater core outlet. 4. I/P. 5. Raise vehicle. 6. Heater hoses to heater core. 7. Lower vehicle. 8. Fill cooling system and check for leaks. 9. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9156 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Specifications Heater Hose: Specifications Heater Outlet Pipe Nut ........................................................................................................................ ...................................................... 25 N.m (18 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses Heater Hose Routing - 2.4L Check all heater hose routing for installation to avoid contact with any obstruction that could result in a damaged hose. Some hoses are equipped with conduit in areas where rubbing may occur. Always reinstall conduit or heat sleeves in the same location when replacing a hose. Tool Required: J 42202 Quick Connect Remover Remove or Disconnect 1. Drain engine coolant. 2. Heater hose from heater pipe by squeezing tabs on quick-connect. ^ J 42202 can be used to separate quick-connect and retainer from pipe. 3. Heater hose from inlet housing. 4. Raise vehicle. 5. Heater hoses from heater core. Install or Connect 1. Heater hoses to heater core. 2. Lower vehicle. 3. Top heater core hose to inlet housing. 4. Heater hose to heater pipe quick-connect, pull to verify connection. 5. Refill engine coolant. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 9162 Heater Hose: Service and Repair Heater Outlet Pipe ^ Part of the coolant pump outlet assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 9163 Heater Hose: Service and Repair Quick Connect Retainer The quick connect retainer can be removed from the heater pipe and replaced if necessary. it is recommended that the retainer be replaced whenever the quick-connect is disconnected. If the retainer is to be reused, the use of J 42202 is recommended. Tool Required: J 42202 Quick Connect Remover 1. Clamp J 42202 around the heater pipe. 2. Slide J 42202 under the quick connect retainer 3. Apply pressure towards the quick connect retainer until the ramps release from the pipe. 4. Remove the quick connect retainer from the pipe. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications High Pressure Safety Valve HVAC: Specifications Compressor Pressure Relief Valve Bolt ................................................................................................................................................ 9.0 N.m (6.1 lbs.ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > A/C Compressor Compressor Components - Disassembled View Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > A/C Compressor > Page 9169 V-5 Compressor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 9170 High Pressure Safety Valve HVAC: Description and Operation The compressor is equipped with a pressure relief valve which is placed in the system as a safety factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure. To prevent system damage, the valve is designed to open automatically when high side pressure exceeds a specified amount. Conditions that might cause this valve to open (defective A/C pressure sensor, inoperative electric cooling fan, etc.) should be corrected, and the refrigerant oil and refrigerant should be replaced as necessary. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve V5 Compressor Rear Head Details Remove or Disconnect 1. Recover refrigerant using J 39500-GM. 2. remove old pressure relief valve. Install or Connect 1. Clean valve seal area on rear head. 2. Lubricate O-ring of new pressure relief valve and O-ring assembly with new 525 viscosity refrigerant oil. Install new valve and torque in place, 9.0 N.m (6.1 lbs. ft.). 3. Evacuate and recharge the system. 4. Leak test systems. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve > Page 9173 High Pressure Safety Valve HVAC: Service and Repair Pressure Relief Valve Direct Mounted V5 Compressor Rear Head Details Remove or Disconnect 1. Recover refrigerant using J 39500-GM. 2. Remove old pressure relief valve. Install or Connect 1. Clean valve seat area on rear head. 2. Lubricate O-ring of new pressure relief valve and O-ring assembly with new 525 viscosity refrigerant oil. Install new valve and torque in place, 9.0 N.m (6.1 lbs.ft.). 3. Evacuate and recharge the system. 4. Leak test system. Conventional Mounted V5 Compressor Rear Head Details Remove or Disconnect Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve > Page 9174 1. Recover refrigerant using J 39500-GM. 2. Remove old pressure relief valve. Install or Connect 1. Clean valve seat area on rear head. 2. Lubricate O-ring of new pressure relief valve and O-ring assembly with new 525 viscosity refrigerant oil. Install new valve and torque in place, 9.0 N.m (6.1 lbs.ft.). 3. Evacuate and recharge the system. 4. Leak test system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: Customer Interest A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 9183 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged Hose/Line HVAC: All Technical Service Bulletins A/C - High Pitched Noise Heard When Compressor Engaged Bulletin No.: 04-01-38-014A Date: March 17, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: High-Pitched Tone Heard Inside Vehicle When A/C Compressor Is Engaged (Replace Compressor Discharge Hose Assembly) Models: 2003-2006 Cadillac Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL 1500 Series Vehicles Only with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front Only Air Conditioning (RPOs CJ2 and CJ3) and a Short Condenser 2005-2006 Cadillac Escalade, Escalade ESV 2005-2006 Chevrolet Suburban, Tahoe 2005-2006 GMC Yukon, Yukon XL 1500 Series Vehicles Only, Built in February 2005 or Later, with 4.8L, 5.3L or 6.0L Engine (RPOs LM7, LQ4, LQ9, LR4 and L59) and Front and Rear Air Conditioning (RPOs CJ2, CJ3 and C69) and a Short Condenser Attention: Parts are released for 1500 series vehicles with front only air conditioning and certain utilities with front and rear air conditioning. The length of the condenser on the utilities must be measured before ordering a new part. Only utilities with a short condenser have a new part released for them. Utility vehicles that are within the model year ranges above but have a long condenser are not covered by this bulletin. Supercede: This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin Number 04-01-38-014. Please discard Corporate Bulletin Number 04-01-38-014 (Section 01 - HVAC). Condition Some customers may comment on a high-pitched tone that is heard inside the vehicle when the Air Conditioning (A/C) compressor is engaged. Cause This condition may be caused by refrigerant pulsations within the A/C system. The noise occurs between 800 and 1000 RPM and is often called an "Off-Idle" noise. This noise is detectable only when the A/C is on. Correction Technicians are to verify that the customer concern is heard when the A/C is on and that it goes away when the A/C is turned off. Verify that the noise is heard at low engine RPMs only, typically between 800 and 1000 RPM. The noise is not measurable above 1200 RPM or below 700 RPM. If the customer concern is present, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly and all other possible sources of the noise are eliminated, then replace the A/C compressor discharge hose assembly. Use the proper part number hose as described in the parts information box below. Use a new hex head bolt, P/N 11515757, to attach the new hose to the A/C compressor discharge port. Verify that the noise has been eliminated and that the A/C system operates normally. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-01-38-014A > Mar > 06 > A/C - High Pitched Noise Heard When Compressor Engaged > Page 9189 Parts Information Important: Some of the utility vehicles listed in this bulletin were built with two different length condensers. All the pickups and utilities with front only air conditioning will have short condenser, but the utilities with rear air conditioning were built with both short and long condensers. This changeover occurred in February 2005. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering any parts when working on a utility with rear A/C. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 9195 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 9201 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 9202 Hose/Line HVAC: Specifications A/C Compressor and Condenser Hose Bolt .............................................................................................................................................. 33 N.m (24 lb. ft.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 9203 Evaporator Tube And Accumulator Tube Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 9204 Hose/Line HVAC: Service and Repair Compressor/Condenser Hose Assembly - 2.2L Compressor/Condenser Hose Assembly - 2.4L Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Switch connection on discharge line. 3. Cruise control module (if equipped). 4. Suction line (accumulator to compressor) at accumulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 9205 5. Upper closeout panel. 6. Connection at the condenser. 7. Raise vehicle. 8. Block fitting at the rear head of the compressor. 9. Compressor/condenser hose assembly. Important ^ Remove and discard all used O-ring seals and "Sealing Washers". Install or Connect 1. Compressor/condenser hose assembly. 2. Block fitting to rear head of compressor using new "Sealing Washers". 3. Lower vehicle. 4. Suction line at the accumulator using a new O-ring seal. 5. Connection at the condenser using new O-ring seals. 6. Switch connection on discharge line. 7. Cruise control module. 8. Upper closeout panel. 9. Evacuate and charge A/C system. 10. Check system operation and leak test. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Heater Module Housing Assembly HVAC: Specifications Heater Module Heater and Vent Module Screws ......................................................................................................... ....................................................... 3 N.m (37 lb. in.) Heater and Vent Module Stud ............................................................................................................. ....................................................... 3 N.m (37 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Specifications > Heater Module > Page 9210 Housing Assembly HVAC: Specifications HVAC Module Heater and Vent Module Screws ......................................................................................................... ....................................................... 3 N.m (37 lb. in.) Heater and Vent Module Stud ............................................................................................................. ....................................................... 3 N.m (37 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Heater Module Heater Module To Dash Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Heater Module > Page 9213 HVAC Module To Dash Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Diagrams > Heater Module Housing Assembly HVAC: Diagrams Heater Module Heater Module - Disassembled View (1 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Diagrams > Heater Module > Page 9216 Heater Module - Disassembled View - Key (2 Of 2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Diagrams > Heater Module > Page 9217 Housing Assembly HVAC: Diagrams HVAC Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Diagrams > Heater Module > Page 9218 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Module Housing Assembly HVAC: Service and Repair Heater Module Heater Module To Dash Panel Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Raise vehicle. 4. Heater hoses at the heater core. 5. Module attaching bolts. 6. Lower the vehicle. 7. I/P and I/P tie bar. 8. Floor air outlet. 9. Wiring harness from module. 10. Electrical connections at blower motor and blower resistor. 11. Module from the vehicle. Install or Connect 1. Module in the vehicle. 2. Electrical connections at blower motor and blower resistor. 3. Wiring harness to module. 4. Floor air outlet. 5. I/P tie bar and I/P. 6. Raise vehicle. 7. Module attaching bolts (upper first then lower). 8. Heater hoses at heater core. 9. Lower vehicle. 10. Fill cooling system. 11. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Module > Page 9221 Housing Assembly HVAC: Service and Repair HVAC Module HVAC Module To Dash Panel Tool Required: J 39500 R-134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Negative battery cable. 2. Drain cooling system. 3. Recover refrigerant. 4. Raise vehicle. 5. Evaporator lines from evaporator. 6. Heater hoses at the heater core. 7. Module attaching bolts. 8. Lower the vehicle. 9. I/P and I/P tie bar. 10. Floor air outlet. 11. Wiring harness from module. 12. Electrical connections at blower motor and blower resistors. 13. Module from the vehicle. Install or Connect 1. Module in the vehicle. 2. Electrical connections at blower motor and blower resistors. 3. Wiring harness to module. 4. Floor air outlet. 5. I/P tie bar and I/P. 6. Raise vehicle. 7. Module attaching bolts (upper first then lower). 8. Heater hoses at heater core and evaporator lines at evaporator. 9. Lower vehicle. 10. Evacuate and charge A/C system. 11. Fill cooling system. 12. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9226 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9227 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9228 Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recharge Equipment File In Section: 01 - HVAC Bulletin No.: 99-01-38-006A Date: May, 2000 WARRANTY ADMINISTRATION Subject: J-43600 ACR 2000 Essential Refrigerant Recovery/Recharge Equipment Models: 1993-2000 Passenger Cars and Light Duty Trucks with R-134a Refrigerant This bulletin is being revised to change the effective date and to update the text. Please discard Corporate Bulletin Number 99-01-38-006 (Section 01 - HVAC). Effective June 1, 2000, the use of J-43600 ACR 2000 will be required on all repairs that require A/C system recovery and are reimbursable by GM. Additionally, GM highly recommends that J-43600 ACR 2000 be used on all GM cars and trucks for customer paid A/C repairs. Important: Also effective June 1, 2000, the "Add" time for all air conditioning recovery is revised to 0.5 hours for front systems and 0.7 hours for front/rear dual systems (RPO C69 or C34). After June 1, 2000, all air conditioning claims submitted with the 0.9 hours "Add" time will be rejected for "labor hours excessive". After the completion of repairs (charging), the ACR 2000 will prompt the user to perform a snapshot of the air conditioning system operating data. The snapshot includes: ^ Maximum high side pressure. ^ Minimum low side pressure. ^ Duct outlet temperatures (2). ^ Refrigerant purity information. This information is captured on a paper printout and in a warranty code. For all GM paid repairs, the paper printout should be attached to the shop copy of the repair order. The warranty code must be submitted in the warranty claim information in the comments field. The code enables the reporting of valuable information about the repair to GM for product quality improvement. Claims submitted without this information may be subject to review and subsequent debit. The required use of J-43600 ACR 2000 raises the question of the acceptable uses for any existing recovery/recycle equipment that GM dealers are currently using. GM recognizes that many of the previously essential ACR4's are reaching the end of their useful life. There are several alternatives for existing equipment that may be considered: ^ Use the existing equipment as customer paid recovery only equipment. Example: Collision repair area. ^ Use the existing equipment as a scavenger unit for contaminated A/C systems. ^ Sell the existing units to repair facilities outside the GM dealer network. ^ Discontinue the use of the existing units if the repair/maintenance costs exceed the value of the equipment. ^ Donate the existing equipment to local technical schools. ^ Dedicate the ACR4 to A/C system flushing, using the J-42939 Flush Adapter. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 9229 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ...................................................... 0.68 kg (1.5 lbs.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 9232 Refrigerant: Fluid Type Specifications Refrigerant Type R-134a GM P/N 12345922 Or Equivalent Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications The A/C system requires 240 ml (8 fl. oz.) of Polyalkylene Glycol (PAG) refrigerant oil. NOTE: Always refer to underhood label as your primary specification resource. Polyalkylene glycol (PAG) refrigerant oil must be added to the system when components are replaced, as follows: 1. All Compressors (drain and measure the oil). a Drain oil out both the suction and discharge ports of the replacement as well as the old compressor. b. Remove compressor crankcase drain bolt and drain oil from compressor crankcase. - If less than 30 ml (1 oz.) is drained - add 60 ml (2 oz.) to the new compressor. - If more than 30 ml (1 oz.) is drained - add same amount that was drained to the new compressor. c. Install compressor crankcase drain bolt. - Tighten compressor crankcase bolt to 20 N.m (15 lbs. ft.). - Up to 120 ml (4 fluid ounces) of oil can collect in the crankcase. Therefore, it is important when replacing a compressor that the oil in the old compressor crankcase be drained and measured (discard the old oil after recording the amount). 2. Receiver Dehydrator ^ Add 105 ml (3.5 oz.) to receiver dehydrator. 3. Evaporator ^ Add 90 ml (3 oz.) oil. 4. Condenser ^ Add 30 ml (1 oz.) oil. 6. Refrigerant oil loss due to a large leak: ^ If the refrigerant charge is abruptly lost due to a large refrigerant leak, approximately 90 ml (3 oz.) of refrigerant oil will be carried out of the system with the refrigerant. Any failure that causes an abrupt refrigerant discharge will experience this oil loss. Failures that allow the refrigerant to seep or bleed off over time do not experience this oil loss. ^ Upon replacement of a component which caused a large refrigerant leak, add 90 ml (3 oz.) of new polyalkylene glycol (PAG) refrigerant oil plus: the required amount of oil for the particular component (as outlined above). NOTE: Add the oil directly to the replaced component if possible. If the oil cannot easily be added to the replaced part, add the oil to the receiver dehydrator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 9239 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Polyalkylene Glycol (PAG) Synthetic Refrigerant Lubricant Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Pressure Transducer .................................................................................................................... ....................................................... 5 N.m (44 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9243 RH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9244 Refrigerant Pressure Sensor / Switch: Description and Operation PURPOSE A/C Refrigerant Pressure Sensor The Air Conditioning (A/C) refrigerant pressure sensor provides a signal to the Powertrain Control Module (PCM) which indicates varying high side refrigerant pressure between approximately 0 psi and 450 psi. OPERATION The PCM uses this input in order to determine the A/C compressor load on the engine in order to help control idle speed with the IAC valve. The A/C refrigerant pressure sensor electrical circuit consists of a 5 volt reference line and a ground line, both provided by the PCM, and a signal line to the PCM. The signal is a voltage that varies from approximately 0.1 volt at 0 psi, to 4.9 volts at 450 psi or more. A problem in the A/C refrigerant pressure circuits or sensor may set a DTC P0530 and will make the A/C compressor inoperative. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9245 Refrigerant Pressure Sensor / Switch: Testing and Inspection A scan tool displays A/C refrigerant pressure in psi. The sensor's range and corresponding display should be in the range of 0 to 450 psi. A sensor or circuit problem should set DTC P0530. A poor ground at the sensor will result in a fixed high pressure value on the scan tool display. Refer to A/C Compressor Clutch Control Diagnosis 2.4L for further diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Pressure Sensor Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Sensor The A/C system has a pressure sensor mounted on the compressor/condenser hose assembly near the condenser connection. The sensor performs both low and high pressure cut-out functions through an input to the PCM. No compressor mounted switches are used. The sensor is mounted on a service fitting and can be replaced without discharging the A/C system. Remove or Disconnect 1. Negative battery cable. 2. Electrical connection at the sensor. 3. Pressure sensor and discard the O-ring seal. ^ The sensor is mounted on a service fitting; do not discharge the system. Install or Connect 1. New O-ring seal lubricated in clean 525 viscosity refrigerant oil. 2. Pressure sensor. 3. Electrical connection at the sensor. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Pressure Sensor > Page 9248 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Sensor Schrader Valve The Schrader valve is located under the A/C pressure sensor in the compressor discharge hose. Tools Required: J 24182-2A Valve Core Remover/Installer J 39500 R- 134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Harness from pressure sensor. 3. Pressure sensor from fitting. 4. Schrader valve from fitting. Install or Connect 1. New valve to fitting. 2. Pressure sensor to fitting. 3. Harness to pressure sensor. 4. Recharge A/C system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair Remove or Disconnect 1. Negative battery cable. 2. I/P trim plate. 3. Control assembly screws and pull control assembly away from the I/P. 4. Blower switch knob. 5. Electrical connection. 6. Blower switch retaining screws and blower switch. Install or Connect 1. Blower switch and retaining screws. 2. Electrical connection. 3. Blower switch knob. 4. Control assembly and retaining screws. 5. I/P trim plate. 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Pressure Transducer .................................................................................................................... ....................................................... 5 N.m (44 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9256 RH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9257 Refrigerant Pressure Sensor / Switch: Description and Operation PURPOSE A/C Refrigerant Pressure Sensor The Air Conditioning (A/C) refrigerant pressure sensor provides a signal to the Powertrain Control Module (PCM) which indicates varying high side refrigerant pressure between approximately 0 psi and 450 psi. OPERATION The PCM uses this input in order to determine the A/C compressor load on the engine in order to help control idle speed with the IAC valve. The A/C refrigerant pressure sensor electrical circuit consists of a 5 volt reference line and a ground line, both provided by the PCM, and a signal line to the PCM. The signal is a voltage that varies from approximately 0.1 volt at 0 psi, to 4.9 volts at 450 psi or more. A problem in the A/C refrigerant pressure circuits or sensor may set a DTC P0530 and will make the A/C compressor inoperative. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 9258 Refrigerant Pressure Sensor / Switch: Testing and Inspection A scan tool displays A/C refrigerant pressure in psi. The sensor's range and corresponding display should be in the range of 0 to 450 psi. A sensor or circuit problem should set DTC P0530. A poor ground at the sensor will result in a fixed high pressure value on the scan tool display. Refer to A/C Compressor Clutch Control Diagnosis 2.4L for further diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Pressure Sensor Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Sensor The A/C system has a pressure sensor mounted on the compressor/condenser hose assembly near the condenser connection. The sensor performs both low and high pressure cut-out functions through an input to the PCM. No compressor mounted switches are used. The sensor is mounted on a service fitting and can be replaced without discharging the A/C system. Remove or Disconnect 1. Negative battery cable. 2. Electrical connection at the sensor. 3. Pressure sensor and discard the O-ring seal. ^ The sensor is mounted on a service fitting; do not discharge the system. Install or Connect 1. New O-ring seal lubricated in clean 525 viscosity refrigerant oil. 2. Pressure sensor. 3. Electrical connection at the sensor. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Pressure Sensor > Page 9261 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Sensor Schrader Valve The Schrader valve is located under the A/C pressure sensor in the compressor discharge hose. Tools Required: J 24182-2A Valve Core Remover/Installer J 39500 R- 134a Refrigerant Recovery, Recycling, and Recharging Station Remove or Disconnect 1. Recover refrigerant. 2. Harness from pressure sensor. 3. Pressure sensor from fitting. 4. Schrader valve from fitting. Install or Connect 1. New valve to fitting. 2. Pressure sensor to fitting. 3. Harness to pressure sensor. 4. Recharge A/C system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Compressor/Condenser Hose Assembly - 2.4L Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair Vacuum Harness Color Code The vacuum hose harness is located under the instrument panel. Remove or Disconnect 1. Negative battery cable. 2. I/P. 3. Air distribution duct. 4. Vacuum lines at the vacuum actuators. 5. Harness from control assembly. Install or Connect 1. Harness to control assembly. 2. Vacuum lines to the vacuum actuators. 3. Air distribution duct. 4. I/P 5. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations Vacuum Reservoir HVAC: Locations Heater Module - Disassembled View (1 Of 2) The vacuum tank is located on top of the HVAC module. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations > Page 9271 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations > Page 9272 Vacuum Reservoir HVAC: Service and Repair Heater Module - Disassembled View (1 Of 2) The vacuum tank is located on top of the HVAC module. During heavy acceleration the vacuum supply from the intake manifold drops. Under load conditions a check valve in the vacuum tank maintains vacuum so that it will be available for continuous use by the vacuum operated actuators. Remove or Disconnect 1. Negative battery cable. 2. I/P. 3. Air distribution ducts. 4. Vacuum line from tank. 5. Vacuum tank from module. Install or Connect Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations > Page 9273 1. Vacuum tank. 2. Vacuum line to tank. 3. Air distribution ducts. 4. I/P. 5. Negative battery cable. Image Key 1 VALVE HOUSING COVER 2 HEATER/BLOWER MODULE BOLT 3 DEFROSTER VALVE 4 MODE VALVE 5 HEATER-VACUUM TANK 6 HEATER MODULE MOUNTING BRACKET 7 HEATER-CONTROL 8 HEATER VALVE LEVER LINK 9 DEFROSTER VALVE ACTUATOR 10 HEATER CASE 11 HEATER VALVE 12 MODE VALVE ACTUATOR 13 TEMPERATURE VALVE CLIP 14 TEMPERATURE VALVE 15 HEATER CORE SHROUD 16 HEATER CORE 17 HEATER CORE STRAP 18 HEATER COVER 19 HEATER OUTLET 20 HEATER CORE SHROUD SEAL 21 HEATER CORE TUBE AND MOUNT SEAL 22 HEATER CORE SEAL 23 HEATER AND A/C CONTROL SWITCH HARNESS 24 DEFROSTER DUCT 25 BLOWER MOTOR BOLTS 26 BLOWER MOTOR ISOLATOR 27 BLOWER MOTOR 28 BLOWER FAN 29 BLOWER RESISTOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations > Page 9274 30 HEATER CASE SEAL 31 BLOWER AND AIR INLET CASE 32 MOUNTING SEAL 33 AIR INLET HOUSING 34 VACUUM HARNESS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel to the straight ahead position. ^ Remove the key from the ignition switch. 1. The AIR BAG fuse from the I/P fuse block. 2. The I/P sound insulator - (LH). 3. The Connector Position Assurance (CPA) and the driver yellow 2-way connector located at the base of the steering column. 4. The Connector Position Assurance (CPA) and the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9281 IMPORTANT With the AIR BAG fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is normal operation and does not indicate a SIR system malfunction. Enabling the SIR System INSTALL OR CONNECT ^ Remove the key from the ignition switch. 1. The passenger yellow 2-way connector and the CPA located near the base of the steering column. 2. The driver yellow 2-way connector and the CPA located at the base of the steering column. 3. The I/P sound insulator - (LH). 4. The AIR BAG fuse to the I/P fuse block. Staying well away from both air bags, turn the ignition switch to the RUN position. Verify that the AIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9282 BAG warning lamp flashes seven times and then stays off. If the AIR BAG warning lamp does not operate as described, perform the SIR DIAGNOSTIC SYSTEM CHECK. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9283 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn off the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR System prevents deploying of the air bags from the reserve energy supply power. Refer to Disabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure Air Bag: Technical Service Bulletins Air Bag - Module Shipping/Return Procedure File In Section: 9 - Accessories Bulletin No.: 31-90-04A Date: September, 1996 Subject: Supplemental Inflatable Restraint (SIR) Module Shipping/Return Procedure Models: 1993-97 Passenger Cars and Trucks - Equipped with Supplemental Inflatable Restraint (SIR) Modules EXCEPT THE MODELS AND YEARS AS LISTED This bulletin is being revised to update the: models and years affected, the contact telephone numbers and the hazardous classification rating. Various areas of the text and the attachments have also been revised. Please discard Corporate Bulletin Number 319004 (Group Reference Accessories). This bulletin outlines the return procedure for undeployed Supplemental Inflatable Restraint (SIR) modules. Undeployed SIR modules in all vehicles (except models indicated), removed for warranty purposes, are to be returned to Delphi Interior and Lighting Systems, General Motors Corporation. This bulletin outlines procedures that all dealers must follow for shipping undeployed airbag modules. This bulletin is in effect and should be retained at all times at the dealership until superseded by a subsequent bulletin. This return program does NOT apply to dealers in Alaska, Hawaii, US Territories, and foreign countries. SIR modules replaced outside the continental United States should be deployed and disposed of following the procedure outlined in Corporate Bulletin Number 319003R. All other modules (i.e., out of warranty or car scrapped) should be disposed of per Corporate Bulletin Number 319003R. Important: If a vehicle is the subject of a Preliminary Investigation (GM-1241), DO NOT ALTER the SIR system until cleared by the Zone Service Representative. An SIR module returned following a 1241 investigation must be clearly designated by: 1. Indicating on the REPAIR ORDER copy inside the box "SUBJECT TO 1241". 2. Indicating the VIN and vehicle owner on the REPAIR ORDER. 3. Sending photocopies of the REPAIR ORDER to: a. The appropriate Zone service Representative b. Cigna Company GM Central Claims Unit 485 W. Milwaukee Suite 690 Detroit, MI 48202 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9288 Mailing Address: P.O. Box 02489, Detroit, MI 48202 Questions related to handling of 1241 associated SIR modules may be answered by calling: Cigna Company - GM Central Claims Unit, 1-800-888-1491. The U.S. Department of Transportation (DOT) Hazardous Materials Regulations classify SIR modules as the following: ^ Proper Shipping Name: Air Bag Modules ^ Hazardous Class: Class 9 - Air Bag Failure to comply with DOT regulations will result in civil penalties of up to $10,000 per violation or criminal penalties of up to $25,000 per violation and imprisonment. Return Procedure for Supplemental Inflatable Restraint Modules (Undeployed Modules Only) All undeployed SIR modules in all vehicles (except as indicated in the models section of this bulletin), removed for warranty purposes, are to be returned to Delphi Interior and Lighting Systems, General Motors. The following procedure should be followed when returning SIR modules from any location within the continental United States. 1. Packaging Requirements Return undeployed SIR modules in the same carton that was received with the new replacement module. Do not use any carton that has been damaged to the extent that the product will not be protected during the shipment. If you need a replacement carton, contact Delphi Interior and Lighting Systems at (513) 356-2426. ENCLOSE A COPY OF THE REPAIR ORDER, detailing the reason(s) for the SIR module replacement. Close and secure the carton with packaging tape (transparent tape is recommended). All existing labels and markings on the carton must be visible. Important: DO NOT staple container. DO NOT cover any portion of the black and white "Class 9" label or any markings on the carton. 2. Package Labels and Markings Add the names and addresses for the consignee and the consignor. The method of closure cannot interfere with the labels or the markings on the package (see Attachments "A" - Driver Side, and "D" - Passenger Side). 3. Shipping Paper (UPS Hazardous Material Label and Shipper's Certification) The following items on the shipping papers must be completed with the same information as enclosed with the replacement SIR module when received: proper shipping name, hazard class, identification number, packaging group number, "EX" number, and emergency response telephone number. The remaining information should be completed in accordance with Attachments "B" and "E" (Driver Side) and "C" and "F" (Passenger Side). A copy of the emergency response guidelines (see Attachment "G") is enclosed with the replacement SIR module and must be attached to the shipping papers you complete for the SIR module being shipped. 4. Transportation All SIR modules are to be returned using United Parcel Service (UPS) which will require the sender to pre-pay the freight charges. If difficulties arise, contact Delphi Interior and Lighting Systems, General Motors at (513) 356-2426. 5. RETURN ALL SUPPLEMENTAL INFLATABLE RESTRAINT MODULES (EXCEPT FOR THOSE MODELS LISTED IN THIS BULLETIN) TO THE FOLLOWING ADDRESS: Delphi Interior and Light Systems 3249 McCall Avenue Dayton, OH 45417 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9289 ATTACHMENT A DRIVER AIRBAG Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9290 ATTACHMENT B DRIVER SIDE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9291 ATTACHMENT C DRIVER SIDE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9292 ATTACHMENT D PASSENGER AIRBAG Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9293 ATTACHMENT E PASSENGER SIDE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9294 ATTACHMENT F PASSENGER SIDE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag - Module Shipping/Return Procedure > Page 9295 ATTACHMENT G Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 9296 Air Bag: Specifications Inflatable Restraint I/P Module Fasteners ............................................................................................................................................ 10.0 N.m (89 lb in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Inflator Module Center Of Steering Wheel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Inflator Module > Page 9299 RH I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 9300 Air Bag: Description and Operation The inflator modules consist of an inflatable bag and an inflator. An inflator consists of a canister of gas-generating material and an initiating device. The initiator is part of the deployment loop. When the vehicle is in a frontal crash of sufficient force, the inflatable restraint sensing and diagnostic module ( SDM) causes current to flow through the deployment loops. Current passing through the initiator ignites the material in the inflator module. The gas produced from this reaction rapidly inflates the air bag. There is a shorting bar on the inflatable restraint steering wheel module side of the upper steering column connector that connects the inflatable restraint steering wheel module coil to the inflatable restraint steering wheel module. The shorting bar shorts across the inflatable restraint steering wheel module circuits during the disconnection of the upper steering column connector. The shorting of the inflatable restraint steering wheel module circuitry will help prevent unwanted deployment of the air bag when servicing the inflatable restraint steering wheel module, the steering column or other SIR system components. There is a shorting bar on the inflatable restraint I/P module connector that connects to the SIR wiring harness. The shorting bar shorts across the inflatable restraint I/P module circuits during the disconnection of the inflatable restraint I/P module connector. The shorting of the inflatable restraint I/P module circuitry will help prevent unwanted deployment of the air bag when servicing the inflatable restraint I/P module, the instrument panel or other SIR system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module Air Bag: Service and Repair Deployed Inflator Module Install or Connect INSTALL OR CONNECT 1. The inflatable restraint I/P module to the vehicle. 2. The fasteners to the inflatable restraint I/P module. TIGHTEN ^ The fasteners to 10 Nm (89 lb in.). 3. The inflatable restraint I/P module pigtail harness to the I/P harness clips. 4. The I/P trim pad. ^ Enable the SIR system, refer to "Enabling the SIR System." Preliminary Precautions After the inflator module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by-products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by-product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will he present after deployment. As with many service procedures, you should wear gloves and safety glasses. Remove or Disconnect REMOVE OR DISCONNECT ^ Disable the SIR system, refer to "Disabling the SIR System." See: Air Bag(s) Arming and Disarming/Service and Repair 1. The I/P trim pad. 2. The inflatable restraint I/P module pigtail harness from the I/P harness clips. 3. The fasteners from the inflatable restraint I/P module. 4. The inflatable restraint I/P module from the vehicle. CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9303 Air Bag: Service and Repair Deployment Procedures Inside of Vehicle (Vehicle Scrapping Procedure) Figure 27 Figure 28 Deploy the inflator modules inside the vehicle when destroying the vehicle. Deploy the inflator modules inside the vehicle when salvaging the vehicle for component parts. This includes, but is not limited to the following situations: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9304 ^ The vehicle has completed its useful life. ^ Irreparable damage occurs to the vehicle in a non-deployment type accident. ^ Irreparable damage occurs to the vehicle during theft. ^ You are salvaging the vehicle for component parts to use on a vehicle with a different Vehicle Identification Number (VIN) as opposed to rebuilding as the same VIN. Never use SIR components from another vehicle. This ensures SIR system integrity. Always use new SIR system components, except when obtaining remanufactured parts from an authorized General Motors dealer. CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, or local laws. Figure 29 Figure 30 31 1. Turn the ignition switch to the LOCK position. 2. Remove the key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module, yellow 2-way connector. This connector is located near the base of the steering column. 6. Cut the inflatable restraint steering wheel module yellow 2-way harness connector from the vehicle. Leave at least 16 cm (6 in) of wire at the connector (Figure 22). 7. Strip 13 mm (0.5 in) of insulation from each wire lead of the connector (Figure 22). 8. Cut two 4.6 m (15 feet) deployment wires from 0.8 mm2 (18 gauge) or thicker multi-strand wire. Use these wires to fabricate the driver deployment harness. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9305 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to Immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. 10. Short the wires by twisting together one end from each (Figure 23). Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. 11. Twist together one connector wire lead to one deployment wire. The connection must be mechanically secure (Figure 241). 12. Bend flat the twisted connection that you made in the previous step. Secure the connection by wrapping tightly with electrical tape. this will also insulate the connection (Figure 242). 13. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire (Figure 243). 14. Connect the deployment harness to the inflatable restraint steering wheel module, yellow 2-way connector at the base of the steering column. 15. Route deployment harness out the driver side of the vehicle (Figure 25). CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. 16. Disconnect inflatable restraint I/P module, yellow 2-way connector. This connector is located above the RH sound insulator. 17. Cut the inflatable restraint I/P module harness connector from the vehicle. Leave at least 16 cm (6 in) of wire at the connector (Figure 26). 18. Strip 13 mm (0.5 in) of insulation from each wire lead of the connector (Figure 26). 19. Cut two 6.1 m (20 feet) deployment wires from 0.8 mm2 (18 gauge) or thicker multi-strand wire. Use these wires to fabricate the passenger deployment harness. 20. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 21. Short the wires by twisting together one end of each (Figure 27). The deployment wires shall remain shorted and not connected to a power source until you are ready to deployed the air bag. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. 22. Twist together one connector wire lead to one deployment wire. The connection must be mechanically secure (Figure 28-1). 23. Bend flat the twisted connection that you made in the previous step. Secure the connection by wrapping tightly with electrical tape. This will also insulate the connection (Figure 28-2). 24. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire (Figure 28-3). 25. Connect the deployment harness to the inflatable restraint I/P module, yellow 2-way connector. 26. Route deployment harness out the passenger side of the vehicle (Figure 33). 27. Be sure to clear the inside of the vehicle and the area surrounding the vehicle of any people. Clear the vehicle of all loose or flammable objects. 28. Stretch the driver and passenger deployment harnesses to their full length (Figures 25 and 29). 29. Completely cover windshield area and front door window openings with a drop cloth, blanket or similar item. This reduces the possibility of injury due to possible fragmentation of the vehicle's glass or interior. 30. Notify everyone in the immediate area that you intend to deploy the air bags. The deployment will be very loud. This may startle any uninformed people in the area. 31. Place a power source near the shorted end of the SIR deployment harness. Use a vehicle battery when available, but always use a power source that complies to the following: ^ 12 volts minimum. ^ 2 amps minimum. 32. Separate the two ends of the driver deployment harness wires (Figure 30). CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9306 ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. NOTICE: The rapid gas expansion involved with deploying an air bag will be very loud. Notify all people in the immediate area that you intend to deploy the inflator modules. 33. Connect the SIR deployment harness wires to the power source to immediately deploy the inflatable restraint steering wheel module (Figure 30). 34. Disconnect the deployment harness wires from the power source. 35. Separate the two ends of the passenger deployment harness wires (Figure 31). CAUTION: Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. The inflator module will immediately deploy the air bag when a power source is connected to it. Connecting the deployment wires to the power source should always be the final step in the inflator module deployment procedure. Failure to follow procedures in the order listed could result in personal injury. 36. Connect the passenger deployment harness wires to a power source. This will immediately deploy the inflatable restraint I/P module (Figure 31). After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. CAUTION: Immediately following the deployment of an air bag, the metal surfaces of the inflator module are very hot. Do not place the deployed inflator module near any flammable objects. Wait for about ten minutes before touching any metal surface of the inflator module. Disregarding these precautions may cause fire or personal injury. The metal canister and the area surrounding the inflator module are very hot. Do not touch the metal areas of the inflator module for about ten minutes after deployment. If you must move the deployed inflator module, use caution. Always wear gloves and handle the inflator module by the air bag or the vinyl trim (Figure 21). 37. Disconnect the deployment harness wires from the power source. 38. Short the driver deployment harness wires by twisting together one end from each of the wires together. Repeat this procedure for the passenger deployment harness. 39. Carefully remove the drop cloth from the vehicle. 40. Disconnect the driver deployment harness and the passenger deployment harness from the vehicle. 41. Discard both deployment harnesses. 42. After deploying both air bags, you may scrap the vehicle in the same manner as a non-SIR equipped vehicle. 43. In the unlikely event that either or both of the inflator modules did not deploy after following these procedures, proceed immediately with Steps 44 through 46. 44. Remove the undeployed inflator module(s) from the vehicle. See: CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 45. Temporarily store the inflator module with its vinyl trim cover facing up. 46. Call the Technical Assistance group for further assistance. Steering Wheel Module TOOLS REQUIRED: J 38826 SIR Deployment Harness Deploy the inflator module(s) outside of the vehicle when you intend to return the vehicle to service. Situations that require deploying the inflator module outside the vehicle include the following: ^ Using the SIR Diagnostics, you determine the inflator module does not function correctly. ^ The inflator module is cosmetically damaged such as a scratch or rip in the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9307 Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. You must follow these inflator module deployment procedures exactly. Always wear safety glasses during this deployment procedure. Do not remove your safety glasses until the deployed inflator module is scrapped or shipped. Before performing the deployment procedures you should be familiar with servicing the SIR system and with proper handling of the inflator module. Procedures should be read fully before they are performed. The following procedures requires the use of: ^ J 38826 SIR Deployment Harness ^ The appropriate pigtail adapter Do not attempt the procedure without J 38826 SIR Deployment Harness and the adapter. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Clear a space on the ground about 1.85 meters (6 feet) in diameter where the inflator module will be deployed. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. IMPORTANT ^ This information applies only to inflatable restraint steering wheel modules. Refer to "Deployment Outside Vehicle (Inflatable Restraint I/P Module)" for information on inflatable restraint I/P module scrapping. See: Outside of Vehicle/Instrument Panel Module 1. Turn the ignition switch to the LOCK position. 2. Remove the key. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9308 Figure 16 Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9309 Figure 20 Figure 21 3. Put on safety glasses. 4. Inspect J 38826 SIR Deployment Harness and appropriate pigtail adapter for damage. If damage occurs to the SIR deployment harness or the pigtail adapter, then obtain a replacement. 5. Short the two SIR deployment harness leads together by fully seating one banana plug into the other. ^ Keep the SIR deployment harness shorted until the air bag is to be deployed (Figure 14). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9310 ^ Do not connect the SIR deployment harness to a power source until the air bag is to be deployed (Figure 14). 6. Connect the appropriate pigtail adapter to the SIR deployment harness (Figure 14). 7. Remove the inflatable restraint steering wheel module from the vehicle. 8. Remove the horn lead from the back of the inflatable restraint steering wheel module, if applicable. 9. Remove the redundant steering wheel control lead(s) from the back of the inflatable restraint steering wheel module, if applicable. 10. Remove all horn buttons and steering wheel control buttons from the inflatable restraint steering wheel module, if applicable. CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 11. Place the inflatable restraint steering wheel module with its vinyl trim cover facing up and away from the surface on a work bench or another surface (Figure 15). 12. Place the inflatable restraint steering wheel module away from all loose or flammable objects. 13. Clear a space on the ground about 1.85 m (6 ft) in diameter where you intend to deploy the inflatable restraint steering wheel module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 14. Make sure no loose or flammable objects are within the deployment area (Figure 16). 15. Place the inflatable restraint steering wheel module in the space just cleared, with its vinyl trim cover facing up (Figure 16). 16. Extend the SIR deployment harness and the pigtail adapter to full length from the inflatable restraint steering wheel module (Figure 17). 17. Place a power source near the shorted end of the SIR deployment harness. Use a vehicle battery when available, but always use a power source that complies to the following: ^ 12 volts minimum. ^ 2 amps minimum. IMPORTANT ^ Firmly seat the pigtail adapter into the inflatable restraint steering wheel module connector. Failure to fully seat the connectors may result in non-deployment of the inflator module. 18. Connect the inflatable restraint steering wheel module to the pigtail adapter on the SIR deployment harness. ^ The deployment harness shall remain shorted until you are ready to deploy the air bag (Figure 14). ^ Do not connect the SIR deployment harness to a power source until you are ready to deploy the air bag (Figure 14). ^ The inflator module will immediately deploy when you connect the power source. 19. Clear the area of all people and loose or flammable objects. 20. Make sure that you place the inflatable restraint steering wheel module with its vinyl trim cover facing up. 21. Notify all people in the immediate area before you deploy the inflatable restraint steering wheel module. ^ An inflatable restraint steering wheel module deployment is very loud. ^ The deployment may startle any uninformed people in the area. 22. Separate the two banana plugs on the SIR deployment harness (Figure 19). CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. NOTICE: When the air bag deploys, the inflatable restraint steering wheel module may jump about 30 cm (one foot) vertically. This is a normal reaction of the inflatable restraint steering wheel module to the force of the rapid gas expansion inside the air bag. NOTICE: The rapid gas expansion involved with deploying an air bag is very loud. Notify all people in the immediate area that you intend to deploy the inflatable restraint steering wheel module. 23. Connect the SIR deployment harness wires to the power source. This immediately deploys the inflatable restraint steering wheel module (Figure 20). 24. Use a vehicle battery when available, but always use a power source that complies to the following: ^ 12 volts minimum. ^ 2 amps minimum. 25. Disconnect the SIR deployment harness from the power source. 26. Short the SIR deployment harness leads together by fully seating one banana plug into the other (Figure 14). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9311 27. In the unlikely event that the inflatable restraint steering wheel module did not deploy after following these procedures, proceed immediately with Steps 33 through 36. If the inflatable restraint steering wheel module did deploy, proceed with Steps 28 through 32. 28. Put on a pair of shop gloves to protect your hands from possible heat and irritation when handling the deployed inflatable restraint steering wheel module. After the inflatable restraint steering wheel module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. CAUTION: Immediately following the deployment of an air bag, the metal surfaces of the inflator module are very hot. Do not place the deployed inflator module near any flammable objects. Wait for about ten minutes before touching any metal surface of the inflator module. Disregarding these precautions may cause fire or personal injury. The metal canister and the area surrounding the inflatable restraint steering wheel module are very hot. Do not touch the metal areas of the inflatable restraint steering wheel module for about ten minutes after deployment. If you must move the deployed inflatable restraint steering wheel module, use caution. Always wear gloves and handle the inflatable restraint steering wheel module by the air bag or the vinyl trim (Figure 21). 29. Disconnect the pigtail adapter from the inflatable restraint steering wheel module as soon after the deployment as possible. This will prevent the hot inflatable restraint steering wheel module canister from damaging the pigtail adapter, or the SIR deployment harness. The pigtail adapter and the SIR deployment harness are reusable. 30. Inspect the pigtail adaptor, and the SIR deployment harness for damage after each use. Replace the pigtail adapter, or the SIR deployment harness, as necessary. 31. Allow the deployed inflatable restraint steering wheel module to cool for at least 10 minutes. Dispose of the deployed inflatable restraint steering wheel module through the normal refuse channels. 32. Wash your hands with a mild soap and water. NOTICE: The remaining steps are to be followed in the unlikely event that the inflatable restraint steering wheel module did not deploy after following these procedures. 33. Make sure that you disconnect the SIR deployment harness from the power source. Make sure that you have shorted the two banana plugs together (Figure 14). 34. Disconnect the pigtail adapter from the inflatable restraint steering wheel module. CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 35. Temporarily Store the inflatable restraint steering wheel module with its vinyl trim cover facing up. 36. Call the Technical Assistance group for further assistance. Instrument Panel Module CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, or local laws. General Motors dealers should refer to the latest General Motors Service Bulletins for live (undeployed) inflatable restraint I/P module scrapping and disposal procedures. All others should contact a local General Motors dealership for live inflatable restraint I/P module scrapping and disposal procedures. Dispose of deployed inflatable restraint I/P modules through normal refuse channels. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9312 Air Bag: Service and Repair Driver Air Bag Replacement For removal and replacement procedures of the Steering Wheel Air Bag Module, refer to Steering Wheel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9313 Air Bag: Service and Repair Handling/Shipping/Scrapping Handling A Deployed Inflator Module After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. Scrapping Procedures During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) inflator module. This information covers proper procedures for disposing of a live inflator module. Before you dispose of a live inflator module, you must deploy the inflator module. Do not dispose of live inflator modules through normal refuse channels. CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury it the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, or local laws. Do not deploy the air bag(s) in the following situations: ^ If you replace an inflator module under warranty. You may need to return the inflator module, undeployed, to Delphi Interior and Lighting Systems. Refer to the latest service bulletin regarding SIR shipping procedures. ^ If a vehicle is the subject of a Product Liability Report related to the SIR system and is subject to a Preliminary Investigation (GM- 1241). DO NOT Alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures. ^ If a vehicle is involved in a campaign affecting the inflator modules. Follow instructions in the Campaign Service Bulletin for proper SIR handling and shipping procedures. You can deploy an inflator module inside or outside of the vehicle, The method you use depends upon the final disposition of the vehicle. Read Deployment Outside Vehicle and Deployment Inside Vehicle to decide whether to deploy the inflator module inside or outside of the vehicle. See: Deployment Procedures Shipping Procedures For Live (Undeployed) Inflator Modules Service personnel should refer to the latest Service Bulletins for proper SIR inflator module shipping procedures. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9314 Air Bag: Service and Repair Install or Connect INSTALL OR CONNECT 1. The inflatable restraint I/P module to the vehicle. 2. The fasteners to the inflatable restraint I/P module. TIGHTEN ^ The fasteners to 10 Nm (89 lb in.). 3. The inflatable restraint I/P module pigtail harness to the I/P harness clips. 4. The I/P trim pad. ^ Enable the SIR system, refer to "Enabling the SIR System." Preliminary Precautions After the inflator module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by-products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by-product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will he present after deployment. As with many service procedures, you should wear gloves and safety glasses. Remove or Disconnect REMOVE OR DISCONNECT ^ Disable the SIR system, refer to "Disabling the SIR System." See: Air Bag(s) Arming and Disarming/Service and Repair 1. The I/P trim pad. 2. The inflatable restraint I/P module pigtail harness from the I/P harness clips. 3. The fasteners from the inflatable restraint I/P module. 4. The inflatable restraint I/P module from the vehicle. CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. Inside of Vehicle (Vehicle Scrapping Procedure) Figure 27 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9315 Figure 28 Deploy the inflator modules inside the vehicle when destroying the vehicle. Deploy the inflator modules inside the vehicle when salvaging the vehicle for component parts. This includes, but is not limited to the following situations: ^ The vehicle has completed its useful life. ^ Irreparable damage occurs to the vehicle in a non-deployment type accident. ^ Irreparable damage occurs to the vehicle during theft. ^ You are salvaging the vehicle for component parts to use on a vehicle with a different Vehicle Identification Number (VIN) as opposed to rebuilding as the same VIN. Never use SIR components from another vehicle. This ensures SIR system integrity. Always use new SIR system components, except when obtaining remanufactured parts from an authorized General Motors dealer. CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, or local laws. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9316 Figure 29 Figure 30 31 1. Turn the ignition switch to the LOCK position. 2. Remove the key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the inflatable restraint steering wheel module, yellow 2-way connector. This connector is located near the base of the steering column. 6. Cut the inflatable restraint steering wheel module yellow 2-way harness connector from the vehicle. Leave at least 16 cm (6 in) of wire at the connector (Figure 22). 7. Strip 13 mm (0.5 in) of insulation from each wire lead of the connector (Figure 22). 8. Cut two 4.6 m (15 feet) deployment wires from 0.8 mm2 (18 gauge) or thicker multi-strand wire. Use these wires to fabricate the driver deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to Immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. 10. Short the wires by twisting together one end from each (Figure 23). Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the air bag. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9317 11. Twist together one connector wire lead to one deployment wire. The connection must be mechanically secure (Figure 241). 12. Bend flat the twisted connection that you made in the previous step. Secure the connection by wrapping tightly with electrical tape. this will also insulate the connection (Figure 242). 13. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire (Figure 243). 14. Connect the deployment harness to the inflatable restraint steering wheel module, yellow 2-way connector at the base of the steering column. 15. Route deployment harness out the driver side of the vehicle (Figure 25). CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. 16. Disconnect inflatable restraint I/P module, yellow 2-way connector. This connector is located above the RH sound insulator. 17. Cut the inflatable restraint I/P module harness connector from the vehicle. Leave at least 16 cm (6 in) of wire at the connector (Figure 26). 18. Strip 13 mm (0.5 in) of insulation from each wire lead of the connector (Figure 26). 19. Cut two 6.1 m (20 feet) deployment wires from 0.8 mm2 (18 gauge) or thicker multi-strand wire. Use these wires to fabricate the passenger deployment harness. 20. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 21. Short the wires by twisting together one end of each (Figure 27). The deployment wires shall remain shorted and not connected to a power source until you are ready to deployed the air bag. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. 22. Twist together one connector wire lead to one deployment wire. The connection must be mechanically secure (Figure 28-1). 23. Bend flat the twisted connection that you made in the previous step. Secure the connection by wrapping tightly with electrical tape. This will also insulate the connection (Figure 28-2). 24. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire (Figure 28-3). 25. Connect the deployment harness to the inflatable restraint I/P module, yellow 2-way connector. 26. Route deployment harness out the passenger side of the vehicle (Figure 33). 27. Be sure to clear the inside of the vehicle and the area surrounding the vehicle of any people. Clear the vehicle of all loose or flammable objects. 28. Stretch the driver and passenger deployment harnesses to their full length (Figures 25 and 29). 29. Completely cover windshield area and front door window openings with a drop cloth, blanket or similar item. This reduces the possibility of injury due to possible fragmentation of the vehicle's glass or interior. 30. Notify everyone in the immediate area that you intend to deploy the air bags. The deployment will be very loud. This may startle any uninformed people in the area. 31. Place a power source near the shorted end of the SIR deployment harness. Use a vehicle battery when available, but always use a power source that complies to the following: ^ 12 volts minimum. ^ 2 amps minimum. 32. Separate the two ends of the driver deployment harness wires (Figure 30). CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. NOTICE: The rapid gas expansion involved with deploying an air bag will be very loud. Notify all people in the immediate area that you intend to deploy the inflator modules. 33. Connect the SIR deployment harness wires to the power source to immediately deploy the inflatable restraint steering wheel module (Figure 30). 34. Disconnect the deployment harness wires from the power source. 35. Separate the two ends of the passenger deployment harness wires (Figure 31). CAUTION: Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. The inflator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9318 module will immediately deploy the air bag when a power source is connected to it. Connecting the deployment wires to the power source should always be the final step in the inflator module deployment procedure. Failure to follow procedures in the order listed could result in personal injury. 36. Connect the passenger deployment harness wires to a power source. This will immediately deploy the inflatable restraint I/P module (Figure 31). After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. CAUTION: Immediately following the deployment of an air bag, the metal surfaces of the inflator module are very hot. Do not place the deployed inflator module near any flammable objects. Wait for about ten minutes before touching any metal surface of the inflator module. Disregarding these precautions may cause fire or personal injury. The metal canister and the area surrounding the inflator module are very hot. Do not touch the metal areas of the inflator module for about ten minutes after deployment. If you must move the deployed inflator module, use caution. Always wear gloves and handle the inflator module by the air bag or the vinyl trim (Figure 21). 37. Disconnect the deployment harness wires from the power source. 38. Short the driver deployment harness wires by twisting together one end from each of the wires together. Repeat this procedure for the passenger deployment harness. 39. Carefully remove the drop cloth from the vehicle. 40. Disconnect the driver deployment harness and the passenger deployment harness from the vehicle. 41. Discard both deployment harnesses. 42. After deploying both air bags, you may scrap the vehicle in the same manner as a non-SIR equipped vehicle. 43. In the unlikely event that either or both of the inflator modules did not deploy after following these procedures, proceed immediately with Steps 44 through 46. 44. Remove the undeployed inflator module(s) from the vehicle. See: CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 45. Temporarily store the inflator module with its vinyl trim cover facing up. 46. Call the Technical Assistance group for further assistance. Steering Wheel Module TOOLS REQUIRED: J 38826 SIR Deployment Harness Deploy the inflator module(s) outside of the vehicle when you intend to return the vehicle to service. Situations that require deploying the inflator module outside the vehicle include the following: ^ Using the SIR Diagnostics, you determine the inflator module does not function correctly. ^ The inflator module is cosmetically damaged such as a scratch or rip in the cover. ^ The inflator module pigtail (if equipped) is damaged. ^ The inflator module connector is damaged. ^ An inflator module connector terminal is damaged. Deployment and disposal of a malfunctioning inflator module is subject to any required retention period. You must follow these inflator module deployment procedures exactly. Always wear safety glasses during this deployment procedure. Do not remove your safety glasses until the deployed inflator module is scrapped or shipped. Before performing the deployment procedures you should be familiar with servicing the SIR system and with proper handling of the inflator module. Procedures should be read fully before they are performed. The following procedures requires the use of: ^ J 38826 SIR Deployment Harness ^ The appropriate pigtail adapter Do not attempt the procedure without J 38826 SIR Deployment Harness and the adapter. CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9319 ^ Wear safety glasses throughout the procedures. ^ Clear a space on the ground about 1.85 meters (6 feet) in diameter where the inflator module will be deployed. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. IMPORTANT ^ This information applies only to inflatable restraint steering wheel modules. Refer to "Deployment Outside Vehicle (Inflatable Restraint I/P Module)" for information on inflatable restraint I/P module scrapping. See: Deployment Procedures/Outside of Vehicle/Instrument Panel Module 1. Turn the ignition switch to the LOCK position. 2. Remove the key. Figure 16 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9320 Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9321 Figure 20 Figure 21 3. Put on safety glasses. 4. Inspect J 38826 SIR Deployment Harness and appropriate pigtail adapter for damage. If damage occurs to the SIR deployment harness or the pigtail adapter, then obtain a replacement. 5. Short the two SIR deployment harness leads together by fully seating one banana plug into the other. ^ Keep the SIR deployment harness shorted until the air bag is to be deployed (Figure 14). ^ Do not connect the SIR deployment harness to a power source until the air bag is to be deployed (Figure 14). 6. Connect the appropriate pigtail adapter to the SIR deployment harness (Figure 14). 7. Remove the inflatable restraint steering wheel module from the vehicle. 8. Remove the horn lead from the back of the inflatable restraint steering wheel module, if applicable. 9. Remove the redundant steering wheel control lead(s) from the back of the inflatable restraint steering wheel module, if applicable. 10. Remove all horn buttons and steering wheel control buttons from the inflatable restraint steering wheel module, if applicable. CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 11. Place the inflatable restraint steering wheel module with its vinyl trim cover facing up and away from the surface on a work bench or another surface (Figure 15). 12. Place the inflatable restraint steering wheel module away from all loose or flammable objects. 13. Clear a space on the ground about 1.85 m (6 ft) in diameter where you intend to deploy the inflatable restraint steering wheel module. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9322 14. Make sure no loose or flammable objects are within the deployment area (Figure 16). 15. Place the inflatable restraint steering wheel module in the space just cleared, with its vinyl trim cover facing up (Figure 16). 16. Extend the SIR deployment harness and the pigtail adapter to full length from the inflatable restraint steering wheel module (Figure 17). 17. Place a power source near the shorted end of the SIR deployment harness. Use a vehicle battery when available, but always use a power source that complies to the following: ^ 12 volts minimum. ^ 2 amps minimum. IMPORTANT ^ Firmly seat the pigtail adapter into the inflatable restraint steering wheel module connector. Failure to fully seat the connectors may result in non-deployment of the inflator module. 18. Connect the inflatable restraint steering wheel module to the pigtail adapter on the SIR deployment harness. ^ The deployment harness shall remain shorted until you are ready to deploy the air bag (Figure 14). ^ Do not connect the SIR deployment harness to a power source until you are ready to deploy the air bag (Figure 14). ^ The inflator module will immediately deploy when you connect the power source. 19. Clear the area of all people and loose or flammable objects. 20. Make sure that you place the inflatable restraint steering wheel module with its vinyl trim cover facing up. 21. Notify all people in the immediate area before you deploy the inflatable restraint steering wheel module. ^ An inflatable restraint steering wheel module deployment is very loud. ^ The deployment may startle any uninformed people in the area. 22. Separate the two banana plugs on the SIR deployment harness (Figure 19). CAUTION: When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed: ^ Wear safety glasses throughout the procedures. ^ Make sure the area around the inflator module is clear of all people and loose or flammable objects. ^ Short the deployment harness wires as instructed. ^ Connect the deployment harness to the inflator module before you connect it to the power source. ^ Connect the deployment harness to the power source to immediately deploy the air bag. Failure to follow the procedures in the order listed may result in personal injury. NOTICE: When the air bag deploys, the inflatable restraint steering wheel module may jump about 30 cm (one foot) vertically. This is a normal reaction of the inflatable restraint steering wheel module to the force of the rapid gas expansion inside the air bag. NOTICE: The rapid gas expansion involved with deploying an air bag is very loud. Notify all people in the immediate area that you intend to deploy the inflatable restraint steering wheel module. 23. Connect the SIR deployment harness wires to the power source. This immediately deploys the inflatable restraint steering wheel module (Figure 20). 24. Use a vehicle battery when available, but always use a power source that complies to the following: ^ 12 volts minimum. ^ 2 amps minimum. 25. Disconnect the SIR deployment harness from the power source. 26. Short the SIR deployment harness leads together by fully seating one banana plug into the other (Figure 14). 27. In the unlikely event that the inflatable restraint steering wheel module did not deploy after following these procedures, proceed immediately with Steps 33 through 36. If the inflatable restraint steering wheel module did deploy, proceed with Steps 28 through 32. 28. Put on a pair of shop gloves to protect your hands from possible heat and irritation when handling the deployed inflatable restraint steering wheel module. After the inflatable restraint steering wheel module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. CAUTION: Immediately following the deployment of an air bag, the metal surfaces of the inflator module are very hot. Do not place the deployed inflator module near any flammable objects. Wait for about ten minutes before touching any metal surface of the inflator module. Disregarding these precautions may cause fire or personal injury. The metal canister and the area surrounding the inflatable restraint steering wheel module are very hot. Do not touch the metal areas of the inflatable restraint steering wheel module for about ten minutes after deployment. If you must move the deployed inflatable restraint steering wheel module, use caution. Always wear gloves and handle the inflatable restraint steering wheel module by the air bag or the vinyl trim (Figure 21). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9323 29. Disconnect the pigtail adapter from the inflatable restraint steering wheel module as soon after the deployment as possible. This will prevent the hot inflatable restraint steering wheel module canister from damaging the pigtail adapter, or the SIR deployment harness. The pigtail adapter and the SIR deployment harness are reusable. 30. Inspect the pigtail adaptor, and the SIR deployment harness for damage after each use. Replace the pigtail adapter, or the SIR deployment harness, as necessary. 31. Allow the deployed inflatable restraint steering wheel module to cool for at least 10 minutes. Dispose of the deployed inflatable restraint steering wheel module through the normal refuse channels. 32. Wash your hands with a mild soap and water. NOTICE: The remaining steps are to be followed in the unlikely event that the inflatable restraint steering wheel module did not deploy after following these procedures. 33. Make sure that you disconnect the SIR deployment harness from the power source. Make sure that you have shorted the two banana plugs together (Figure 14). 34. Disconnect the pigtail adapter from the inflatable restraint steering wheel module. CAUTION: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 35. Temporarily Store the inflatable restraint steering wheel module with its vinyl trim cover facing up. 36. Call the Technical Assistance group for further assistance. Instrument Panel Module CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, or local laws. General Motors dealers should refer to the latest General Motors Service Bulletins for live (undeployed) inflatable restraint I/P module scrapping and disposal procedures. All others should contact a local General Motors dealership for live inflatable restraint I/P module scrapping and disposal procedures. Dispose of deployed inflatable restraint I/P modules through normal refuse channels. Driver Air Bag Replacement For removal and replacement procedures of the Steering Wheel Air Bag Module, refer to Steering Wheel. Handling A Deployed Inflator Module After the inflator module has deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the deployment. Gloves and safety glasses are recommended, however, as a precaution. Gloves and safety glasses help to prevent possible irritation of the skin or eyes. Scrapping Procedures During the course of a vehicle's useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) inflator module. This information covers proper procedures for disposing of a live inflator module. Before you dispose of a live inflator module, you must deploy the inflator module. Do not dispose of live inflator modules through normal refuse channels. CAUTION: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury it the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, or local laws. Do not deploy the air bag(s) in the following situations: ^ If you replace an inflator module under warranty. You may need to return the inflator module, undeployed, to Delphi Interior and Lighting Systems. Refer to the latest service bulletin regarding SIR shipping procedures. ^ If a vehicle is the subject of a Product Liability Report related to the SIR system and is subject to a Preliminary Investigation (GM- 1241). DO NOT Alter the SIR system in any manner. Refer to the latest service bulletin on SIR shipping procedures. ^ If a vehicle is involved in a campaign affecting the inflator modules. Follow instructions in the Campaign Service Bulletin for proper SIR handling and shipping procedures. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Deployed Inflator Module > Page 9324 You can deploy an inflator module inside or outside of the vehicle, The method you use depends upon the final disposition of the vehicle. Read Deployment Outside Vehicle and Deployment Inside Vehicle to decide whether to deploy the inflator module inside or outside of the vehicle. See: Deployment Procedures Shipping Procedures For Live (Undeployed) Inflator Modules Service personnel should refer to the latest Service Bulletins for proper SIR inflator module shipping procedures. Live (Undeployed) Inflator Module WARNINGS: 1. When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. 2. Take special care when handling and storing a live (undeployed) inflator module. Air bag deployment produces rapid gas generation. This may cause the inflator module, or an object in front of the inflator module, to jettison through the air in the unlikely event of an accidental deployment. 3. When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. when you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical Provide free space for the air bag to expand in case of an accidental deployment. 4. Personal injury may result from any mishandling of the inflator module. For air bag inflator module service procedures, refer to Steering Column / Service and Repair. Passenger's Inflator Module PASSENGER INFLATOR MODULE Removal ^ Disable SIR system. 1. I/P trim pad. 2. Connector Position Assurance (CPA) and electrical connector. 3. Fasteners from passenger inflator module. 4. Passenger inflator module from vehicle. Install 1. Passenger inflator module from vehicle. 2. Fasteners from passenger inflator module. Tighten Fasteners to 2.3 Nm (20.4 lb. in.). 3. Electrical connector and CPA. 4. I/P trim pad. ^ Enable SIR system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment Technical Service Bulletin # 98026 Date: 980818 US Version CAMPAIGN: INADVERTENT AIR BAG DEPLOYMENT # 98026 - (08/18/1998) NOTE: THE CANADIAN VERSION OF 98026 IS ALSO SHOWN. PRODUCT CAMPAIGNS 98026 AUGUST, 1998 SUBJECT: 98026 - INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODELS THE HIGHWAY SAFETY ACT, AS AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A RECALL CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A REASONABLE TIME AFTER THE CUSTOMER HAS TENDERED IT FOR REPAIR. A FAILURE TO REPAIR WITHIN SIXTY (60) DAYS AFTER TENDER OF A VEHICLE IS PRIMA FACIE EVIDENCE OF FAILURE TO REPAIR WITHIN A REASONABLE TIME. IF THE CONDITION IS NOT ADEQUATELY REPAIRED WITHIN A REASONABLE TIME, THE CUSTOMER MAY BE ENTITLED TO AN IDENTICAL OR REASONABLY EQUIVALENT VEHICLE AT NO CHARGE OR TO A REFUND OF THE PURCHASE PRICE LESS A REASONABLE ALLOWANCE FOR DEPRECIATION. TO AVOID HAVING TO PROVIDE THESE BURDENSOME REMEDIES, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH CUSTOMER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE COPY OF THE DIVISIONAL LETTER THAT IS BEING SENT TO CUSTOMERS, THE CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE (5) DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THEY ARE INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION. DEFECT INVOLVED GENERAL MOTORS HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 J CARS. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9333 INVOLVED ARE CERTAIN 1996-97 'J' MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTICE: DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) PRIOR TO BEGINNING CAMPAIGN REPAIRS. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM STATE MOTOR VEHICLE REGISTRATION RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF LAW IN SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION CUSTOMERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER SHOWN IN THIS BULLETIN ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALERS' POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE DIVISIONAL CUSTOMER LETTER ACCOMPANYING THIS BULLETIN. CAMPAIGN FOLLOW-UP CARDS SHOULD NOT BE USED FOR THIS PURPOSE, SINCE THE CUSTOMER MAY NOT AS YET HAVE RECEIVED THE NOTIFICATION LETTER. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, PLEASE TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9334 1. RETURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY". 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. 23. INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9335 EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. WHEN INSTALLING THE CAMPAIGN IDENTIFICATION LABEL, BE SURE TO PULL THE TAB TO ALLOW ADHESION OF THE CLEAR PROTECTIVE COVERING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM VISPAC INCORPORATED BY CALLING 1-800-269-5100 (MONDAY-FRIDAY, 8:00 A.M. TO 4:30 P.M. EST). ASK FOR ITEM NUMBER S-1015 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Canadian Version GM OF CANADA VERSION PRODUCT CAMPAIGNS 98026 AUGUST 1998 SUBJECT: CAMPAIGN 98026 INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE DEFECT INVOLVED GENERAL MOTORS OF CANADA LIMITED HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9336 VEHICLES INVOLVED INVOLVED ARE CERTAIN 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM THE INTER-PROVINCIAL RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF PROVINCIAL LAWS. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION ALL CUSTOMERS OF RECORD AT THE TIME OF CAMPAIGN RELEASE ARE SHOWN ON THE COMPUTER LISTING AND HAVE BEEN NOTIFIED BY FIRST CLASS MAIL FROM GENERAL MOTORS (SEE COPY OF CUSTOMER LETTER SHOWN IN THIS BULLETIN). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALER'S POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE CUSTOMER LETTER SHOWN IN THIS BULLETIN. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU MUST TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9337 IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). 1. TURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOUR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY" 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9338 23. INSTALL CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL." EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. INSERT CAMPAIGN NUMBER INSERT DEALER CODE EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM DGN BY CALLING 1-800-668-5539 (MONDAY-FRIDAY, 8:00 A.M. TO 5:00 P.M. EST). ASK FOR ITEM NUMBER GMP 91 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9339 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9340 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Air Bag Control Module: Recalls Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment Technical Service Bulletin # 98026 Date: 980818 US Version CAMPAIGN: INADVERTENT AIR BAG DEPLOYMENT # 98026 - (08/18/1998) NOTE: THE CANADIAN VERSION OF 98026 IS ALSO SHOWN. PRODUCT CAMPAIGNS 98026 AUGUST, 1998 SUBJECT: 98026 - INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODELS THE HIGHWAY SAFETY ACT, AS AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A RECALL CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A REASONABLE TIME AFTER THE CUSTOMER HAS TENDERED IT FOR REPAIR. A FAILURE TO REPAIR WITHIN SIXTY (60) DAYS AFTER TENDER OF A VEHICLE IS PRIMA FACIE EVIDENCE OF FAILURE TO REPAIR WITHIN A REASONABLE TIME. IF THE CONDITION IS NOT ADEQUATELY REPAIRED WITHIN A REASONABLE TIME, THE CUSTOMER MAY BE ENTITLED TO AN IDENTICAL OR REASONABLY EQUIVALENT VEHICLE AT NO CHARGE OR TO A REFUND OF THE PURCHASE PRICE LESS A REASONABLE ALLOWANCE FOR DEPRECIATION. TO AVOID HAVING TO PROVIDE THESE BURDENSOME REMEDIES, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH CUSTOMER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE COPY OF THE DIVISIONAL LETTER THAT IS BEING SENT TO CUSTOMERS, THE CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE (5) DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THEY ARE INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION. DEFECT INVOLVED GENERAL MOTORS HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 J CARS. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9350 INVOLVED ARE CERTAIN 1996-97 'J' MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTICE: DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) PRIOR TO BEGINNING CAMPAIGN REPAIRS. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM STATE MOTOR VEHICLE REGISTRATION RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF LAW IN SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION CUSTOMERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER SHOWN IN THIS BULLETIN ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALERS' POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE DIVISIONAL CUSTOMER LETTER ACCOMPANYING THIS BULLETIN. CAMPAIGN FOLLOW-UP CARDS SHOULD NOT BE USED FOR THIS PURPOSE, SINCE THE CUSTOMER MAY NOT AS YET HAVE RECEIVED THE NOTIFICATION LETTER. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, PLEASE TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9351 1. RETURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY". 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. 23. INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9352 EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. WHEN INSTALLING THE CAMPAIGN IDENTIFICATION LABEL, BE SURE TO PULL THE TAB TO ALLOW ADHESION OF THE CLEAR PROTECTIVE COVERING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM VISPAC INCORPORATED BY CALLING 1-800-269-5100 (MONDAY-FRIDAY, 8:00 A.M. TO 4:30 P.M. EST). ASK FOR ITEM NUMBER S-1015 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Canadian Version GM OF CANADA VERSION PRODUCT CAMPAIGNS 98026 AUGUST 1998 SUBJECT: CAMPAIGN 98026 INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE DEFECT INVOLVED GENERAL MOTORS OF CANADA LIMITED HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9353 VEHICLES INVOLVED INVOLVED ARE CERTAIN 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM THE INTER-PROVINCIAL RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF PROVINCIAL LAWS. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION ALL CUSTOMERS OF RECORD AT THE TIME OF CAMPAIGN RELEASE ARE SHOWN ON THE COMPUTER LISTING AND HAVE BEEN NOTIFIED BY FIRST CLASS MAIL FROM GENERAL MOTORS (SEE COPY OF CUSTOMER LETTER SHOWN IN THIS BULLETIN). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALER'S POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE CUSTOMER LETTER SHOWN IN THIS BULLETIN. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU MUST TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9354 IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). 1. TURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOUR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY" 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9355 23. INSTALL CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL." EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. INSERT CAMPAIGN NUMBER INSERT DEALER CODE EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM DGN BY CALLING 1-800-668-5539 (MONDAY-FRIDAY, 8:00 A.M. TO 5:00 P.M. EST). ASK FOR ITEM NUMBER GMP 91 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9356 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9357 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Air Bag Control Module: All Technical Service Bulletins Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 9362 Air Bag Control Module: Specifications Inflatable Restraint Sensing and Diagnostic Module Fasteners 10.0 N.m (89 lb in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > System Component Locations Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > System Component Locations > Page 9365 Under RH Front Seat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9366 Sensing Diagnostic Module (SDM) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9367 Air Bag Control Module: Description and Operation CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the SDM horizontally on the mounting surface. ^ Point the arrow on the SDM toward the front of the vehicle. ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9368 The inflatable restraint sensing and diagnostic module (SDM) performs the following functions in the SIR system. ^ Energy Reserve-The SDM maintains 23 Volt Loop Reserve (23 VLR) energy supplies to provide deployment energy. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Frontal Crash Detection-The SDM monitors vehicle velocity changes to detect frontal crashes that are severe enough to warrant deployment. ^ Air Bag Deployment-During a frontal crash of sufficient force, the SDM will cause enough current to flow through the inflator modules to deploy the air bags. ^ Frontal Crash Recording-The SDM records information regarding the SIR system status during a frontal crash. ^ Malfunction Detection-The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a diagnostic trouble code. ^ Malfunction Diagnosis-The SDM displays SIR diagnostic trouble codes and system status information through the use of a scan tool. ^ Driver Notification-The SDM warns the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp. The SDM connects to the SIR wiring harness using a 12-way connector. The SDM harness connector uses a shorting bar across certain terminals in the contact area. Removal of the SDM Connector Position Assurance (CPA) or the harness connector itself will connect the AIR BAG warning lamp to ground through the shorting bar. The AIR BAG warning lamp will come ON steady with power applied to the SDM when either one of the following two conditions exist: ^ You remove the SDM CPA. ^ You disconnect the SDM harness connector. The SDM receives power whenever the ignition switch is at the RUN or START positions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions Air Bag Control Module: Service and Repair Important Preliminary Precautions CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the SDM horizontally on the mounting surface. ^ Point the arrow on the SDM toward the front of the vehicle. ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the Sensing and Diagnostic Module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming for instructions on how to disable the SIR system. See: Air Bag(s) Arming and Disarming/Service and Repair With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of Significant soaking is detected, you MUST: ^ Remove all water ^ Repair the water damage ^ Replace the SDM harness connector ^ Replace the SDM Failure to follow these procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9371 Air Bag Control Module: Service and Repair Install or Connect INSTALL OR CONNECT 1. The inflatable restraint Sensing and Diagnostic Module (SDM) to the vehicle, make sure the arrow is pointing toward the front of the vehicle. 2. The SDM fasteners. TIGHTEN ^ Fasteners to 10 N.m (89 lb in.). 3. The electrical connector and the CPA. 4. The carpet and the passenger front carpet retainer. 5. The passenger front seat. ^ Enable the SIR system, refer to "Enabling the SIR System." See: Air Bag(s) Arming and Disarming/Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9372 Air Bag Control Module: Service and Repair Remove or Disconnect REMOVE OR DISCONNECT ^ Disable the SIR system, Refer to "Disabling the SIR System." See: Air Bag(s) Arming and Disarming/Service and Repair 1. The passenger front seat. 2. The passenger front carpet retainer, then roll back the carpet. 3. The Connector Position Assurance (CPA) and the electrical connector. 4. The fasteners from the inflatable restraint sensing and diagnostic module. 5. The inflatable restraint Sensing and Diagnostic Module (SDM) from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9373 Air Bag Control Module: Service and Repair Repair of Mounting Studs and/or Bracket First Repair IMPORTANT ^ The following repair procedures should only he used in the event that the Sensing and Diagnostic Module (SDM) mounting fasteners are damaged to the extent that the SDM can no longer be properly mounted. FIRST REPAIR 1. Remove and discard the fastener. 2. Use a new fastener (P/N 10156138). 3. Torque the fastener to 10 N.m (89 lb in.). Second Repair IMPORTANT ^ The following repair procedures should only he used in the event that the Sensing and Diagnostic Module (SDM) mounting fasteners are damaged to the extent that the SDM can no longer be properly mounted. SECOND REPAIR 1. Remove and discard the fastener. 2. Use a larger fastener (P/N 10267482) with washer (P/N 11500305). 3. Torque the fastener to 15.0 N.m (134 lb in.). Use hand tools only to achieve fastener torque. This will prevent stripping of the replacement fastener. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Safety Switch/Connector > Component Information > Locations LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > SIR Coil Assembly <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Component Locations SIR Coil Assembly: Component Locations LH Front Lower Engine Compartment Center Of Steering Wheel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > SIR Coil Assembly <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Component Locations > Page 9381 LH Lower I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > SIR Coil Assembly <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 9382 SIR Coil Assembly: Description and Operation The inflatable restraint steering wheel module coil consists of two or more current-carrying coils. The inflatable restraint steering wheel module coil attaches to the steering column. Two of the current-carrying coils allow rotation of the steering wheel while maintaining continuous contact of the driver deployment loop to the inflatable restraint steering wheel module. There is a shorting bar on the yellow 2-way connector near the base of the steering column that connects the inflatable restraint steering wheel module coil to the SIR wiring harness. The shorting bar shorts the circuits to the inflatable restraint steering wheel module coil and inflatable restraint steering wheel module during the disconnection of the yellow 2-way connector. The shorting of the inflatable restraint steering wheel module coil and inflatable restraint steering wheel module circuitry will help prevent unwanted deployment of the air bag when servicing the steering column or other SIR system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > SIR Coil Assembly <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service and Repair > Centering Steering Wheel Inflator Module Coil Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > SIR Coil Assembly <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service and Repair > Centering Steering Wheel Inflator Module Coil > Page 9385 SIR Coil Assembly: Service and Repair SIR Coil Assembly NOTE: Refer to Steering Column Unit Repair for additional procedures. REMOVE OR DISCONNECT Important: Disable the Supplemental Inflatable Restraint (SIR) system. 1. Steering wheel assembly. 2. Coil assembly retaining clip. 3. Coil assembly off shaft end letting coil hang freely. 4. Wave washer. 5. Spacer shaft lock (standard column only). 6. Shaft lock retaining ring using J 23563-C to compress lock. 7. Pry off retaining ring. 8. Shaft lock. 9. Turn signal canceling cam assembly. 10. Upper bearing spring. 11. Turn signal to right turn position (up). 12. Multifunction lever. 13. Hazard knob assembly. 14. Screw and signal switch arm. ^ Let switch arm hang freely (tilt option equipped with cruise only). 15. Screws, turn signal switch. ^ Let turn signal switch hang freely. 16. Remove coil assembly connector shroud. 17. Steering column support bracket bolts. 18. Upper steering column bolts. 19. Wiring protector. 20. Connect a length of mechanic's wire to coil assembly terminal connector to aid in reassembly. 21. Gently pull wire harness through steering column housing shroud, steering column housing and lock assembly cover. 22. Remove mechanic's wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > SIR Coil Assembly <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service and Repair > Centering Steering Wheel Inflator Module Coil > Page 9386 INSTALL OR CONNECT NOTICE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. 1. Connect mechanic's wire to centering coil assembly connector. 2. Gently pull connector through steering column housing shroud, steering column housing and lock assembly. 3. Remove mechanic's wire. 4. Install wiring protector. 5. Install connector shroud. 6. Connector centering coil assembly terminal connector. 7. Steering column lower support bracket to steering column. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 8. Steering column upper support bolts. ^ Tighten bolts to 27 Nm (20 ft. lbs.). 9. Turn signal switch assembly. ^ Tighten bolts to 3.4 Nm (30 inch lbs.). 10. Signal switch arm (tilt steering column only). ^ Tighten bolts to 2.3 Nm (20 inch lbs.). 11. Hazard knob assembly. 12. Multifunction lever. 13. Turn signal canceling cam assembly. ^ Lubricate with grease, synthetic (service kit). 14. Shaft lock. ^ Inspect shaft lock retaining ring for damage or deformation. Replace with new retaining ring. 15. Shaft lock retaining ring. Line up to block tooth on shaft using J 23653-C to compress shaft lock. ^ Shaft lock retaining ring must be firmly seated in groove on shaft. 16. Spacer shaft lock (standard column only). 17. Ensure coil assembly is centered. Important: Assemble pre-centered coil assembly to steering column. Remove centering tab and dispose. Important: Coil assembly will become un-centered if: a. Steering column is separated form steering gear and is allowed to rotate. b. Centering spring is pushed down, letting hub rotate while coil is removed from steering column. In the event this occurs, refer to "Centering Coil Assembly." 18. Coil assembly using horn tower on canceling cam assembly inner ring and projections on outer ring for alignment. 19. Coil assembly retaining ring. ^ Ring must be firmly in groove on shaft. Important: Gently pull lower coil assembly wire to remove any wire kinks that may be inside column assembly. It is absolutely critical that you make sure there are no kinks or bends in the SIR coil assembly wire. If a kink or bend is present, interference may occur with the shaft lock mechanism. Then turning of the steering wheel may cut or damage wire. 20. Steering wheel assembly. 21. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Impact Sensor: Recalls Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Impact Sensor: All Technical Service Bulletins Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 9400 Front Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Impact Sensor: Service and Repair Front End Discriminating Sensor The presence of an inflatable restraint front end discriminating sensor enhances the SIR system performance. Use of the inflatable restraint front end discriminating sensor provides timely deployment of the air bags during some crashes. Although this is a mechanical sensor, it is not a part of the deployment loop but instead only provides an input signal to the inflatable restraint sensing and diagnostic module. Caution should be used to ensure proper location of sensors to the mounting brackets. The keying of the sensor to the wiring harness connectors must not be modified for any reason. CAUTION: During service procedures, be very careful when handling a sensor. Never strike or jar a sensor. Under some circumstances, it could cause deployment and result in personal injury or improper operation of the Supplemental Inflatable Restraint (SIR) system. All sensors and mounting bracket bolts must be carefully torqued to assure proper operation. Never power up the SIR system when any sensor is not rigidly attached to vehicle, since the sensor could be activated when not attached and could result in deployment. REMOVE OR DISCONNECT ^ Disable the SIR system. Refer to "Disabling the SIR System." See: Air Bag(s) Arming and Disarming/Service and Repair 1. The Connector Position Assurance (CPA) and the electrical connector. 2. The sensor mounting fasteners. 3. The sensor from the vehicle. IMPORTANT ^ The following repair procedures should only be used in the event that the sensor mounting holes and/or fasteners are damaged to the extent that the sensor can no longer be properly mounted. 1. Remove and discard the fastener. 2. Chisel off the damaged weld nut. 3. Condition the front end lower tie surface where the new weld nut is to he installed. 4. Install the new weld nut (P/N 11514034) into position. 5. Migweld the new weld nut to the front end lower tie surface in the correct location. 6. Use a new fastener (P/N 11515926). CAUTION: Proper operation of the inflatable restraint Front End Discriminating Sensor requires the sensor be rigidly attached to the vehicle structure and the arrow on the sensor be pointing towards the front of the vehicle. INSTALL OR CONNECT 1. The sensor to the vehicle, make sure the arrow is pointing toward the front of the vehicle. 2. The sensor mounting fasteners. TIGHTEN Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9403 ^ The fasteners to 10 N.m (89 lb in.). 3. The electrical connector and the connector position assurance (CPA). ^ Enable the SIR system. Refer to "Enabling the SIR System." See: Air Bag(s) Arming and Disarming/Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9404 Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as "the portion of the vehicle which is crushed, bent, or damaged due to a collision." For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, it must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor Also, if you follow a diagnostic trouble code table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 83-81-34 > Mar > 99 > SIR - Operating Vehicle with Warning Light On Malfunction Lamp / Indicator: Customer Interest SIR - Operating Vehicle with Warning Light On File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-34 Date: March, 1999 INFORMATION Subject: Operating Vehicle with Supplemental Inflatable Restraint (SIR) Warning Light Illuminated Models: 1999 and Prior Passenger Cars and Light Duty Trucks with SDM Controlled Air Bag System The AIR BAG warning light is the key to driver notification of Supplemental Inflatable Restraint (SIR) system malfunctions. When the warning light remains illuminated or continues to flash, one or more of the following conditions may occur if vehicle operation is continued. ^ Non-deployment of the air bags in the event of a crash. ^ Deployment of the air bags without a crash. ^ Deployment of the air bags in crashes less severe than intended. If an AIR BAG warning light is illuminated or flashing, you should advise the customer of these possibilities and that the vehicle should be serviced right away. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-81-34 > Mar > 99 > SIR - Operating Vehicle with Warning Light On Malfunction Lamp / Indicator: All Technical Service Bulletins SIR - Operating Vehicle with Warning Light On File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-34 Date: March, 1999 INFORMATION Subject: Operating Vehicle with Supplemental Inflatable Restraint (SIR) Warning Light Illuminated Models: 1999 and Prior Passenger Cars and Light Duty Trucks with SDM Controlled Air Bag System The AIR BAG warning light is the key to driver notification of Supplemental Inflatable Restraint (SIR) system malfunctions. When the warning light remains illuminated or continues to flash, one or more of the following conditions may occur if vehicle operation is continued. ^ Non-deployment of the air bags in the event of a crash. ^ Deployment of the air bags without a crash. ^ Deployment of the air bags in crashes less severe than intended. If an AIR BAG warning light is illuminated or flashing, you should advise the customer of these possibilities and that the vehicle should be serviced right away. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Malfunction Lamp / Indicator: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) File In Section: 5 - Brakes Bulletin No.: 73-50-26 Date: August, 1997 Subject: ABS Light On - DTC's 46 and 86 Set (Perform Diagnostic Procedure, Replace Center ABS Motor Pinion) Models: 1991-97 Buick Skylark 1992-97 Buick Regal 1994-97 Buick Century 1992-96 Chevrolet Beretta, Corsica, Lumina APV 1992-97 Chevrolet Cavalier, Lumina, 1993-97 Chevrolet Camaro 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Malibu, Venture 1993-97 Geo Prizm 1995-97 Geo Metro 1996-97 Geo Tracker 1991 Oldsmobile Calais 1992-96 Oldsmobile Cutlass Ciera 1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette 1997 Oldsmobile Cutlass 1998 Oldsmobile Intrigue 1991-97 Pontiac Grand Am 1992-94 Pontiac Sunbird 1992-97 Pontiac Grand Prix, Trans Sport 1993-97 Pontiac Firebird, Trans Am 1995-97 Pontiac Sunfire Condition Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as current or history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles). Cause A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded by the EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather is hot and humid. Important: Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause. Correction Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Malfunction Lamp / Indicator: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9427 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Malfunction Lamp / Indicator: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9428 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Malfunction Lamp / Indicator: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9434 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Malfunction Lamp / Indicator: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 9435 Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in for service. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motor pinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft. Pinion Replacement If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a direct replacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Complete motor pack replacement is not required. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time H2506 Use published labor operation time. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Air Bag Warning Lamp Malfunction Lamp / Indicator: Description and Operation Air Bag Warning Lamp The AIR BAG warning lamp indicates the words "AIR BAG" for domestic vehicles. The ignition switch applies ignition voltage to the AIR BAG warning lamp. The AIR BAG warning lamp receives power whenever the ignition switch is at the RUN or START positions. The inflatable restraint sensing and diagnostic module (SDM) controls the lamp by providing ground with a lamp driver. The SIR system uses the AIR BAG warning lamp to do the following: ^ Verify lamp and SDM operation by flashing the lamp seven times when the ignition switch is first turned to the RUN position. ^ Warn the vehicle driver of SIR electrical system malfunctions which could potentially affect the operation of the SIR system. These malfunctions could result in non-deployment in case of a frontal crash or deployment for conditions less severe than intended. The AIR BAG warning lamp is the key to driver notification of SIR system malfunctions. For proper lamp operation, refer to SIR Diagnostic System Check. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Air Bag Warning Lamp > Page 9438 Malfunction Lamp / Indicator: Description and Operation Circuit Description The AIR BAG Indicator is controlled by the Sensing Diagnostic Module (SDM) via serial data with the IPC. The AIR BAG Indicator is designed to alert the driver of a potential SIR system problem which could prevent the proper deployment of the air bag. When the ignition lock cylinder is turned to "RUN", the IPC turns the AIR BAG Indicator "ON" until it receives a valid "turn off" command from the SDM. The AIR BAG Indicator will flash seven (7) times indicating that the SIR system has performed self diagnostics. If the indicator does not go out after the self check, a system malfunction may exist. During a loss of serial data (ignition in "OFF/UNLOCK"), the telltale will light steady. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation The knee bolsters absorb energy and control the forward movement of the vehicle's front seat occupants during a frontal crash, by limiting leg movement. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment Technical Service Bulletin # 98026 Date: 980818 US Version CAMPAIGN: INADVERTENT AIR BAG DEPLOYMENT # 98026 - (08/18/1998) NOTE: THE CANADIAN VERSION OF 98026 IS ALSO SHOWN. PRODUCT CAMPAIGNS 98026 AUGUST, 1998 SUBJECT: 98026 - INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODELS THE HIGHWAY SAFETY ACT, AS AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A RECALL CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A REASONABLE TIME AFTER THE CUSTOMER HAS TENDERED IT FOR REPAIR. A FAILURE TO REPAIR WITHIN SIXTY (60) DAYS AFTER TENDER OF A VEHICLE IS PRIMA FACIE EVIDENCE OF FAILURE TO REPAIR WITHIN A REASONABLE TIME. IF THE CONDITION IS NOT ADEQUATELY REPAIRED WITHIN A REASONABLE TIME, THE CUSTOMER MAY BE ENTITLED TO AN IDENTICAL OR REASONABLY EQUIVALENT VEHICLE AT NO CHARGE OR TO A REFUND OF THE PURCHASE PRICE LESS A REASONABLE ALLOWANCE FOR DEPRECIATION. TO AVOID HAVING TO PROVIDE THESE BURDENSOME REMEDIES, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH CUSTOMER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE COPY OF THE DIVISIONAL LETTER THAT IS BEING SENT TO CUSTOMERS, THE CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE (5) DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THEY ARE INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION. DEFECT INVOLVED GENERAL MOTORS HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 J CARS. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9455 INVOLVED ARE CERTAIN 1996-97 'J' MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTICE: DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) PRIOR TO BEGINNING CAMPAIGN REPAIRS. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM STATE MOTOR VEHICLE REGISTRATION RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF LAW IN SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION CUSTOMERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER SHOWN IN THIS BULLETIN ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALERS' POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE DIVISIONAL CUSTOMER LETTER ACCOMPANYING THIS BULLETIN. CAMPAIGN FOLLOW-UP CARDS SHOULD NOT BE USED FOR THIS PURPOSE, SINCE THE CUSTOMER MAY NOT AS YET HAVE RECEIVED THE NOTIFICATION LETTER. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, PLEASE TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9456 1. RETURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY". 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. 23. INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9457 EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. WHEN INSTALLING THE CAMPAIGN IDENTIFICATION LABEL, BE SURE TO PULL THE TAB TO ALLOW ADHESION OF THE CLEAR PROTECTIVE COVERING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM VISPAC INCORPORATED BY CALLING 1-800-269-5100 (MONDAY-FRIDAY, 8:00 A.M. TO 4:30 P.M. EST). ASK FOR ITEM NUMBER S-1015 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Canadian Version GM OF CANADA VERSION PRODUCT CAMPAIGNS 98026 AUGUST 1998 SUBJECT: CAMPAIGN 98026 INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE DEFECT INVOLVED GENERAL MOTORS OF CANADA LIMITED HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9458 VEHICLES INVOLVED INVOLVED ARE CERTAIN 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM THE INTER-PROVINCIAL RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF PROVINCIAL LAWS. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION ALL CUSTOMERS OF RECORD AT THE TIME OF CAMPAIGN RELEASE ARE SHOWN ON THE COMPUTER LISTING AND HAVE BEEN NOTIFIED BY FIRST CLASS MAIL FROM GENERAL MOTORS (SEE COPY OF CUSTOMER LETTER SHOWN IN THIS BULLETIN). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALER'S POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE CUSTOMER LETTER SHOWN IN THIS BULLETIN. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU MUST TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9459 IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). 1. TURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOUR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY" 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9460 23. INSTALL CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL." EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. INSERT CAMPAIGN NUMBER INSERT DEALER CODE EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM DGN BY CALLING 1-800-668-5539 (MONDAY-FRIDAY, 8:00 A.M. TO 5:00 P.M. EST). ASK FOR ITEM NUMBER GMP 91 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9461 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 98026 > Aug > 98 > Recall Inadvertent Air Bag Deployment > Page 9462 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Air Bag Control Module: Recalls Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment Technical Service Bulletin # 98026 Date: 980818 US Version CAMPAIGN: INADVERTENT AIR BAG DEPLOYMENT # 98026 - (08/18/1998) NOTE: THE CANADIAN VERSION OF 98026 IS ALSO SHOWN. PRODUCT CAMPAIGNS 98026 AUGUST, 1998 SUBJECT: 98026 - INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODELS THE HIGHWAY SAFETY ACT, AS AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A RECALL CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A REASONABLE TIME AFTER THE CUSTOMER HAS TENDERED IT FOR REPAIR. A FAILURE TO REPAIR WITHIN SIXTY (60) DAYS AFTER TENDER OF A VEHICLE IS PRIMA FACIE EVIDENCE OF FAILURE TO REPAIR WITHIN A REASONABLE TIME. IF THE CONDITION IS NOT ADEQUATELY REPAIRED WITHIN A REASONABLE TIME, THE CUSTOMER MAY BE ENTITLED TO AN IDENTICAL OR REASONABLY EQUIVALENT VEHICLE AT NO CHARGE OR TO A REFUND OF THE PURCHASE PRICE LESS A REASONABLE ALLOWANCE FOR DEPRECIATION. TO AVOID HAVING TO PROVIDE THESE BURDENSOME REMEDIES, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH CUSTOMER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE COPY OF THE DIVISIONAL LETTER THAT IS BEING SENT TO CUSTOMERS, THE CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE (5) DAYS OF THE MUTUALLY AGREED UPON SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THEY ARE INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION. DEFECT INVOLVED GENERAL MOTORS HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 J CARS. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). VEHICLES INVOLVED Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9472 INVOLVED ARE CERTAIN 1996-97 'J' MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTICE: DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) PRIOR TO BEGINNING CAMPAIGN REPAIRS. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM STATE MOTOR VEHICLE REGISTRATION RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF LAW IN SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION CUSTOMERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY GENERAL MOTORS (SEE COPY OF TYPICAL CUSTOMER LETTER SHOWN IN THIS BULLETIN ACTUAL DIVISIONAL LETTER MAY VARY SLIGHTLY). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALERS' POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE DIVISIONAL CUSTOMER LETTER ACCOMPANYING THIS BULLETIN. CAMPAIGN FOLLOW-UP CARDS SHOULD NOT BE USED FOR THIS PURPOSE, SINCE THE CUSTOMER MAY NOT AS YET HAVE RECEIVED THE NOTIFICATION LETTER. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, PLEASE TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9473 1. RETURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY". 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. 23. INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9474 EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. WHEN INSTALLING THE CAMPAIGN IDENTIFICATION LABEL, BE SURE TO PULL THE TAB TO ALLOW ADHESION OF THE CLEAR PROTECTIVE COVERING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM VISPAC INCORPORATED BY CALLING 1-800-269-5100 (MONDAY-FRIDAY, 8:00 A.M. TO 4:30 P.M. EST). ASK FOR ITEM NUMBER S-1015 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Canadian Version GM OF CANADA VERSION PRODUCT CAMPAIGNS 98026 AUGUST 1998 SUBJECT: CAMPAIGN 98026 INADVERTENT AIR BAG DEPLOYMENT MODELS: 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE DEFECT INVOLVED GENERAL MOTORS OF CANADA LIMITED HAS DECIDED THERE IS A DEFECT RELATED TO MOTOR VEHICLE SAFETY IN 1996 AND SOME 1997 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S COMPUTER, THERE IS AN INCREASED RISK OF AN AIR BAG DEPLOYMENT IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN. AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED PEOPLE WHO ARE TOO CLOSE TO THEM. EVERY OCCUPANT SHOULD BE PROPERLY RESTRAINED. A REAR-FACING CHILD SEAT SHOULD NEVER BE SECURED IN THE FRONT PASSENGER SEAT BECAUSE OF THE RISK OF SERIOUS INJURY OR DEATH. WE STRONGLY RECOMMEND THAT ALL CHILDREN BE RESTRAINED PROPERLY IN THE REAR SEAT. AFTER A DEPLOYMENT, THE AIR BAG INFLATORS, COMPUTER (SENSING AND DIAGNOSTIC MODULE), STEERING WHEEL PAD, INSTRUMENT PANEL COVER, AND OTHER PARTS MUST BE REPLACED. TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO REPROGRAM THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9475 VEHICLES INVOLVED INVOLVED ARE CERTAIN 1996-97 CHEVROLET CAVALIER AND PONTIAC SUNFIRE MODEL VEHICLES BUILT WITHIN THE VIN BREAKPOINTS SHOWN. NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID. INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER. COMPUTER LISTINGS CONTAINING THE COMPLETE VEHICLE IDENTIFICATION NUMBER, CUSTOMER NAME AND ADDRESS DATA HAVE BEEN PREPARED, AND ARE BEING FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. THE CUSTOMER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH CUSTOMERS INVOLVED IN THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED. THESE DEALER LISTINGS MAY CONTAIN CUSTOMER NAMES AND ADDRESSES OBTAINED FROM THE INTER-PROVINCIAL RECORDS. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY OTHER PURPOSE IS A VIOLATION OF PROVINCIAL LAWS. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING TO THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. PARTS INFORMATION NO PARTS ARE REQUIRED FOR THIS CAMPAIGN. CUSTOMER NOTIFICATION ALL CUSTOMERS OF RECORD AT THE TIME OF CAMPAIGN RELEASE ARE SHOWN ON THE COMPUTER LISTING AND HAVE BEEN NOTIFIED BY FIRST CLASS MAIL FROM GENERAL MOTORS (SEE COPY OF CUSTOMER LETTER SHOWN IN THIS BULLETIN). DEALER CAMPAIGN RESPONSIBILITY ALL UNSOLD NEW VEHICLES IN DEALER'S POSSESSION AND SUBJECT TO THIS CAMPAIGN MUST BE HELD AND INSPECTED/REPAIRED PER THE SERVICE PROCEDURE OF THIS CAMPAIGN BULLETIN BEFORE CUSTOMERS TAKE POSSESSION OF THESE VEHICLES. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO CUSTOMERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. CUSTOMERS WHO HAVE RECENTLY PURCHASED VEHICLES SOLD FROM YOUR VEHICLE INVENTORY, AND FOR WHICH THERE IS NO CUSTOMER INFORMATION INDICATED ON THE DEALER LISTING, ARE TO BE CONTACTED BY THE DEALER. ARRANGEMENTS ARE TO BE MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH CUSTOMERS A COPY OF THE APPROPRIATE CUSTOMER LETTER SHOWN IN THIS BULLETIN. IN SUMMARY, WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN ENTERS YOUR VEHICLE INVENTORY, OR IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU MUST TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE SELLING OR RELEASING THE VEHICLE. SERVICE PROCEDURE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9476 IMPORTANT: THE TECH 2 DIAGNOSTIC TOOL MUST BE UPDATED WITH AUGUST 1998 CD # 15 OR LATER FOR REPROGRAMMING THE AIR BAG SENSING AND DIAGNOSTIC MODULE (SDM). 1. TURN THE IGNITION SWITCH TO THE "ON" POSITION AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". 2. IF THE "AIR BAG" WARNING LAMP DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL BEFORE PROCEEDING. IMPORTANT: DIAGNOSIS, REPAIRS AND/OR PARTS NECESSARY TO ASSURE THAT THE AIR BAG SYSTEM IS FUNCTIONING PROPERLY BEFORE STARTING THE CAMPAIGN SERVICE PROCEDURE SHOULD BE CHARGED UNDER REGULAR WARRANTY LABOUR CODES AND TIMES. 3. CONNECT THE TECH 2 TO THE VEHICLE'S DATA LINK CONNECTOR (DLC) UNDER THE INSTRUMENT PANEL. 4. TURN THE TECH 2 "ON" BY PRESSING THE POWER BUTTON. 5. PRESS "ENTER" TO ACCESS THE "MAIN MENU". 6. USE THE "UP" AND "DOWN" BUTTONS (ARROWS) ON THE TECH 2 TO MOVE THE HIGHLIGHT BAR TO THE SELECTIONS DESCRIBED IN THE FOLLOWING STEPS. 7. SELECT "DIAGNOSTICS" ON THE "MAIN MENU" SCREEN AND PRESS "ENTER". 8. SELECT THE APPROPRIATE MODEL YEAR (1996 OR 1997) ON THE "VEHICLE IDENTIFICATION" SCREEN AND THEN PRESS "ENTER". 9. SELECT "PASSENGER CAR" ON THE "VEHICLE IDENTIFICATION" (TYPES) SCREEN AND PRESS "ENTER". 10. SELECT "BODY" ON THE "SYSTEM SELECTION MENU" SCREEN AND THEN PRESS "ENTER". 11. SELECT THE LETTER "J" ON THE "VEHICLE IDENTIFICATION" (CAR PRODUCT LINES) SCREEN AND PRESS "ENTER". 12. SELECT THE APPROPRIATE GM NAMEPLATE (CHEVROLET OR PONTIAC) ON THE "VEHICLE IDENTIFICATION" SCREEN AND PRESS "ENTER". 13. SELECT "SUPPLEMENTAL INFLATABLE RESTRAINT" ON THE "BODY" SCREEN AND PRESS "ENTER". 14. CONFIRM THAT THE IGNITION SWITCH IS STILL IN THE "ON" POSITION (ENGINE NOT RUNNING). 15. SELECT "PROGRAMMING" ON THE "SUPPLEMENTAL INFLATABLE RESTRAINT" SCREEN AND PRESS "ENTER". 16. SELECT "SDM REPROGRAMMING" ON THE "PROGRAMMING" SCREEN AND PRESS "ENTER". 17. TECH 2 WILL THEN DISPLAY: "KEY MUST BE IN THE ON POSITION. ENGINE MUST BE OFF". 18. PRESS THE "CONTINUE" SOFT KEY TO INITIATE REPROGRAMMING. TECH 2 WILL THEN DISPLAY: "WAITING FOR DATA". FOLLOWED BY: "PROCEDURE IN PROGRESS". IMPORTANT: IF THE VEHICLE HAS PREVIOUSLY HAD THE SDM REPLACED WITH AN UPDATED VERSION, THE TECH-2 WILL DISPLAY: "PROCEDURE NOT REQUIRED". 19. WHEN REPROGRAMMING IS COMPLETE, TECH 2 WILL DISPLAY: "REPROGRAMMING COMPLETED SUCCESSFULLY" 20. AFTER REPROGRAMMING IS COMPLETE, PRESS THE "EXIT" BUTTON ON THE TECH 2. 21. TURN THE IGNITION SWITCH TO "OFF" AND DISCONNECT THE TECH 2 FROM THE VEHICLE'S DLC. 22. TURN THE IGNITION SWITCH TO "ON" AND VERIFY THAT THE "AIR BAG" WARNING LAMP FLASHES SEVEN (7) TIMES AND THEN TURNS "OFF". IF IT DOES NOT OPERATE AS DESCRIBED, PERFORM THE SIR DIAGNOSTIC SYSTEM CHECK AS DESCRIBED IN SECTION 9J OF THE APPROPRIATE SERVICE MANUAL. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9477 23. INSTALL CAMPAIGN IDENTIFICATION LABEL. CAMPAIGN IDENTIFICATION LABEL EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL." EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR A BALL POINT PEN. INSERT CAMPAIGN NUMBER INSERT DEALER CODE EACH "CAMPAIGN IDENTIFICATION LABEL" IS TO BE LOCATED ON THE RADIATOR CORE SUPPORT IN AN AREA WHICH WILL BE VISIBLE WHEN THE VEHICLE IS BROUGHT IN BY THE CUSTOMER FOR PERIODIC SERVICING. ADDITIONAL CAMPAIGN IDENTIFICATION LABELS CAN BE OBTAINED FROM DGN BY CALLING 1-800-668-5539 (MONDAY-FRIDAY, 8:00 A.M. TO 5:00 P.M. EST). ASK FOR ITEM NUMBER GMP 91 WHEN ORDERING. APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE. CLAIM INFORMATION Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9478 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 98026 > Aug > 98 > Recall - Inadvertent Air Bag Deployment > Page 9479 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Air Bag Control Module: All Technical Service Bulletins Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 9484 Air Bag Control Module: Specifications Inflatable Restraint Sensing and Diagnostic Module Fasteners 10.0 N.m (89 lb in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > System Component Locations > Page 9487 Under RH Front Seat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9488 Sensing Diagnostic Module (SDM) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9489 Air Bag Control Module: Description and Operation CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the SDM horizontally on the mounting surface. ^ Point the arrow on the SDM toward the front of the vehicle. ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9490 The inflatable restraint sensing and diagnostic module (SDM) performs the following functions in the SIR system. ^ Energy Reserve-The SDM maintains 23 Volt Loop Reserve (23 VLR) energy supplies to provide deployment energy. Ignition voltage can provide deployment energy if the 23 Volt Loop Reserves malfunction. ^ Frontal Crash Detection-The SDM monitors vehicle velocity changes to detect frontal crashes that are severe enough to warrant deployment. ^ Air Bag Deployment-During a frontal crash of sufficient force, the SDM will cause enough current to flow through the inflator modules to deploy the air bags. ^ Frontal Crash Recording-The SDM records information regarding the SIR system status during a frontal crash. ^ Malfunction Detection-The SDM performs diagnostic monitoring of the SIR system electrical components. Upon detection of a circuit malfunction, the SDM will set a diagnostic trouble code. ^ Malfunction Diagnosis-The SDM displays SIR diagnostic trouble codes and system status information through the use of a scan tool. ^ Driver Notification-The SDM warns the vehicle driver of SIR system malfunctions by controlling the AIR BAG warning lamp. The SDM connects to the SIR wiring harness using a 12-way connector. The SDM harness connector uses a shorting bar across certain terminals in the contact area. Removal of the SDM Connector Position Assurance (CPA) or the harness connector itself will connect the AIR BAG warning lamp to ground through the shorting bar. The AIR BAG warning lamp will come ON steady with power applied to the SDM when either one of the following two conditions exist: ^ You remove the SDM CPA. ^ You disconnect the SDM harness connector. The SDM receives power whenever the ignition switch is at the RUN or START positions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions Air Bag Control Module: Service and Repair Important Preliminary Precautions CAUTION: Be careful when you handle a Sensing and Diagnostic Module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the SDM horizontally on the mounting surface. ^ Point the arrow on the SDM toward the front of the vehicle. ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. CAUTION: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the Sensing and Diagnostic Module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Air Bag(s) Arming and Disarming for instructions on how to disable the SIR system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of Significant soaking is detected, you MUST: ^ Remove all water ^ Repair the water damage ^ Replace the SDM harness connector ^ Replace the SDM Failure to follow these procedures could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9493 Air Bag Control Module: Service and Repair Install or Connect INSTALL OR CONNECT 1. The inflatable restraint Sensing and Diagnostic Module (SDM) to the vehicle, make sure the arrow is pointing toward the front of the vehicle. 2. The SDM fasteners. TIGHTEN ^ Fasteners to 10 N.m (89 lb in.). 3. The electrical connector and the CPA. 4. The carpet and the passenger front carpet retainer. 5. The passenger front seat. ^ Enable the SIR system, refer to "Enabling the SIR System." See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9494 Air Bag Control Module: Service and Repair Remove or Disconnect REMOVE OR DISCONNECT ^ Disable the SIR system, Refer to "Disabling the SIR System." See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair 1. The passenger front seat. 2. The passenger front carpet retainer, then roll back the carpet. 3. The Connector Position Assurance (CPA) and the electrical connector. 4. The fasteners from the inflatable restraint sensing and diagnostic module. 5. The inflatable restraint Sensing and Diagnostic Module (SDM) from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Important Preliminary Precautions > Page 9495 Air Bag Control Module: Service and Repair Repair of Mounting Studs and/or Bracket First Repair IMPORTANT ^ The following repair procedures should only he used in the event that the Sensing and Diagnostic Module (SDM) mounting fasteners are damaged to the extent that the SDM can no longer be properly mounted. FIRST REPAIR 1. Remove and discard the fastener. 2. Use a new fastener (P/N 10156138). 3. Torque the fastener to 10 N.m (89 lb in.). Second Repair IMPORTANT ^ The following repair procedures should only he used in the event that the Sensing and Diagnostic Module (SDM) mounting fasteners are damaged to the extent that the SDM can no longer be properly mounted. SECOND REPAIR 1. Remove and discard the fastener. 2. Use a larger fastener (P/N 10267482) with washer (P/N 11500305). 3. Torque the fastener to 15.0 N.m (134 lb in.). Use hand tools only to achieve fastener torque. This will prevent stripping of the replacement fastener. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel to the straight ahead position. ^ Remove the key from the ignition switch. 1. The AIR BAG fuse from the I/P fuse block. 2. The I/P sound insulator - (LH). 3. The Connector Position Assurance (CPA) and the driver yellow 2-way connector located at the base of the steering column. 4. The Connector Position Assurance (CPA) and the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9501 IMPORTANT With the AIR BAG fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is normal operation and does not indicate a SIR system malfunction. Enabling the SIR System INSTALL OR CONNECT ^ Remove the key from the ignition switch. 1. The passenger yellow 2-way connector and the CPA located near the base of the steering column. 2. The driver yellow 2-way connector and the CPA located at the base of the steering column. 3. The I/P sound insulator - (LH). 4. The AIR BAG fuse to the I/P fuse block. Staying well away from both air bags, turn the ignition switch to the RUN position. Verify that the AIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9502 BAG warning lamp flashes seven times and then stays off. If the AIR BAG warning lamp does not operate as described, perform the SIR DIAGNOSTIC SYSTEM CHECK. See: Air Bag Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9503 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn off the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR System prevents deploying of the air bags from the reserve energy supply power. Refer to Disabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Top Teather Attachment Kits Bulletin No.: 99-09-40-004a Date: April 12, 2005 INFORMATION Subject: Top Tether Hardware Package for Child Restraint Seats Models: 1989-2002 Passenger Cars, Light Duty Trucks and Multi-Purpose Passenger Vehicles (Except EV1 and Prizm) Supercede: This bulletin is being revised to add the 2000-2002 model years. Please discard Corporate Bulletin Number 99-09-40-009 (Section 09 - Restraints). Important: GM of Canada and IPC Dealers are not authorized to utilize this service bulletin. Beginning in August, 1997 General Motors began providing Child Restraint Seat Top Tether Hardware Packages to customers in the United States who requested them. The Top Tether Hardware Package contains the necessary hardware for anchoring a forward facing child restraint seat top tether. One Child Restraint Seat Top Tether Hardware Package will be provided per vehicle to the retail customer at no charge for installation. Charges for installation of additional Top Tether Hardware Packages per vehicle are the responsibility of the customer. Most forward facing child restraint seats (CRS) sold in the United States prior to calendar year 1999 were not sold with top tether straps, but have provisions for them. Top tethers, which are required in Canada, can help to better secure the seat in the vehicle. When a forward facing CRS including a top tether is used, specially designed components must be used to secure the child seat top tether. These components are included in the Hardware Package from GMSPO. Top tethers are not normally required or used with rearward facing infant restraint seats. Rearward facing infant restraint seats should never be secured in the front seat of an air bag equipped vehicle unless the vehicle is equipped with an air bag de-activation (shut-off) switch and the switch has been used to turn the air bag off. Should a retail customer request installation of a Tether Hardware Package at the time of sale or delivery, it is to be installed at no charge to the owner. The labor to install a Tether Hardware Package prior to delivery of a new vehicle to the customer is considered to be part of the delivery "get ready process", and as such, is not claimable. Claiming for the cost and applicable handling allowance of the proper Tether Hardware Package used in the installation is allowed. If the customer requests installation of a Tether Hardware Package some time after delivery, the package is to be provided free of charge. Hardware Packages include installation instructions which are easily followed and can be installed by most customers. However, should the customer request the dealership's assistance to install the Tether Hardware Package, it is to be installed at no charge to the customer and the labor may be claimed. All claims submitted for installation labor of an approved Tether Hardware Package must be supported by a signed customer work order. Additional Hardware Packages and installation charges are the responsibility of the customer. In addition, passenger vehicle deliveries, including vans and sport utilities for daily rental usage, may have one tether hardware package supplied. Additional packages are the owner's responsibility. Dealers may claim appropriate parts under these circumstances. Sufficient quantities of parts should be ordered in advance of the arrival of vehicles to avoid delays. Important: When installing a Child Restraint Seat Top Tether Hardware Package, follow the installation instructions included in the package. Additional information about specific mounting locations and installations may be available in the Seat Belt Section (Sections 9, 10-10, 10-11 or 10A) I of the appropriate Service Manual, or the Restraints section of SI. Any questions regarding this policy should be directed to your Area Manager, Parts or Service. Parts Information For Top Tether Hardware Package part numbers and usage, see Group 14.870 (passenger cars & U-van), or Group 16.710 (Light Duty Truck) of the appropriate GMSPO Parts Catalog. In addition, they can also be found in Accessories Group 21.042. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits > Page 9509 Warranty Information The dealership will be reimbursed for the parts and labor, if applicable, through the submission of a regular warranty claim. All claims submitted must be supported by a signed customer work order. Purchase and installation of additional Hardware Packages is the responsibility of the customer. For Top Tether Hardware Packages installed in the United States, submit as a normal warranty claim using the labor operations and time allowances shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) - Plastic Cover Comes Loose Seat Belt: Customer Interest Seat Shoulder Belt (Front) - Plastic Cover Comes Loose File In Section: 09 - Restraints Bulletin No.: 99-09-40-001 Date: May, 1999 TECHNICAL Subject: Front Seat Shoulder Belt Plastic Cover at Pillar Will Not Stay Fastened (Replace Bolt) Models: 1995-99 Chevrolet Cavalier (Coupe Only) 1995-99 Pontiac Sunfire (Coupe Only) Condition Some customers may comment that the front seat shoulder belt plastic cover will not stay snapped in place. This cover hides the bolt that attaches to the pillar. Correction Replace the shoulder belt to the pillar attaching bolt with new bolt P/N 15674851, using the following service procedure. Inspect the plastic cover for cracks or damage and replace the cover if necessary. Also replace the shoulder belt bolt and inspect the cover on the opposite side of the vehicle. Service Procedure 1. Remove and inspect the plastic cover by pulling on the bottom of the cover (2). 2. Remove the shoulder belt to the pillar attaching bolt (1). 3. Install the new shoulder belt to the pillar attaching bolt (1) and tighten to 42 N.m (31 lb ft). 4. Install the plastic cover over the bolt head (2). 5. Repeat the procedure on the opposite side of the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) - Plastic Cover Comes Loose > Page 9518 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use: Labor Labor Operation Description Time Shoulder Belt to Pillar C9050 Attaching Bolts - Replace Both 0.2 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) - Plastic Cover Comes Loose Seat Belt: All Technical Service Bulletins Seat Shoulder Belt (Front) - Plastic Cover Comes Loose File In Section: 09 - Restraints Bulletin No.: 99-09-40-001 Date: May, 1999 TECHNICAL Subject: Front Seat Shoulder Belt Plastic Cover at Pillar Will Not Stay Fastened (Replace Bolt) Models: 1995-99 Chevrolet Cavalier (Coupe Only) 1995-99 Pontiac Sunfire (Coupe Only) Condition Some customers may comment that the front seat shoulder belt plastic cover will not stay snapped in place. This cover hides the bolt that attaches to the pillar. Correction Replace the shoulder belt to the pillar attaching bolt with new bolt P/N 15674851, using the following service procedure. Inspect the plastic cover for cracks or damage and replace the cover if necessary. Also replace the shoulder belt bolt and inspect the cover on the opposite side of the vehicle. Service Procedure 1. Remove and inspect the plastic cover by pulling on the bottom of the cover (2). 2. Remove the shoulder belt to the pillar attaching bolt (1). 3. Install the new shoulder belt to the pillar attaching bolt (1) and tighten to 42 N.m (31 lb ft). 4. Install the plastic cover over the bolt head (2). 5. Repeat the procedure on the opposite side of the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-09-40-001 > May > 99 > Seat Shoulder Belt (Front) - Plastic Cover Comes Loose > Page 9524 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use: Labor Labor Operation Description Time Shoulder Belt to Pillar C9050 Attaching Bolts - Replace Both 0.2 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9530 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9531 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9537 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 9538 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 9547 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 9553 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 73-83-09 > May > 97 > Cooling - Low Coolant Light On During Sustained Driving Radiator Surge Tank: All Technical Service Bulletins Cooling - Low Coolant Light On During Sustained Driving File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-83-09 Date: May, 1997 Subject: Low Engine Coolant Light On During Sustained Driving at Moderate to High Engine RPM (Replace Cooling System Surge Tank) Models: 1997 Chevrolet Cavalier 1997 Pontiac Sunfire Built from SOP through December 31, 1996 Condition Some owners may comment that the low engine coolant light will illuminate during sustained driving at moderate to high engine RPM. Cause The design of the baffles in the cooling system surge tank coupled with the engine coolant air bleed pipe allow high coolant flow. This may allow the coolant sensor cavity in the surge tank to have an inadequate supply of coolant during sustained driving at moderate to high engine RPM. This may cause the low coolant light to illuminate even if the system is properly filled. Correction Verify that the system is properly filled and free of leaks. If the condition is still present, replace the cooling system surge tank with the revised design (see below for P/N's). Refer to the 1997 Service Manual. Parts Information Old P/N New P/N Description 22600776 22605500 For Chevrolet Cavalier and Pontiac Sunfire Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J3250 Tank, Radiator Use published Coolant Surge - labor operation R&R; or Replace time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical Service Bulletins > Seat Belts - Latch Slides To Seat Belt Anchor Sleeve Seat Belt Latch: Technical Service Bulletins Seat Belts - Latch Slides To Seat Belt Anchor Sleeve File In Section: 10 Body Bulletin No.: 73-16-16A Date: April, 1998 Subject: Seat Belt Latch Slides to Seat Belt Anchor Sleeve (Install Seat Belt Webbing Stop Button) Models: 1996-98 Buick Skylark 1995-98 Chevrolet Cavalier 1997-98 Chevrolet Malibu 1996-98 Oldsmobile Achieva 1999 Oldsmobile Alero 1997-98 Oldsmobile Cutlass 1995-98 Pontiac Sunfire 1996-99 Pontiac Grand Am This bulletin is being revised to update applicable models. Please discard Corporate Bulletin Number 73-16-16 (Section 10 - Body) Condition Some owners may comment that the seat belt latch slides to the seat belt anchor sleeve. Cause The web stop comfort convenience button may have separated from the webbing. Correction Refer to Figure 1. 1. Install seat belt webbing stop button in existing hole. 2. If unable to locate existing hole, remove bolt cap cover at rocker/floor pan mounting and measure from the center of bolt head; place the seat belt webbing stop button in the center of webbing using the following dimensions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical Service Bulletins > Seat Belts - Latch Slides To Seat Belt Anchor Sleeve > Page 9575 ^ Alero and Grand Am (1999), Cavalier, Cutlass and Malibu (Coupe and Sedan) - 460 mm (18 inches). ^ Grand Am (1996-98), Skylark and Achieva (Coupe and Sedan) - 555 mm (22 inches). a. Make sure latch is above the seat belt webbing stop button. b. Use caution when snapping button halves together. c. Remove the sharp point of the male half after installation to prevent scratching or torn clothing. (Small needle nose pliers work well.) Parts Information The following are the button kits for service, consisting of two male and two female buttons. P/N Description 12453514 Medium Dark Oak 12453515 Graphite 12453516 Adriatic Blue 12453517 Medium Neutral (Taupe) 12453518 Medium Pewter 12453519 Dark Teal 12453520 Red Garnet 12453521 Medium Dark Neutral 12453522 Medium Dark Pewter Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C9040/41 0.2 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The Seat Belt Indicator is controlled by the IPC via serial data based on status of the Seat Belt Switch. The status of the Seat Belt Switch is received from the SDM. The indicator will light when ignition is in the "RUN" or "CRANK" positions and the driver's safety belt is not fastened. Also, the Multi-Function Alarm Module will sound when the Ignition Switch is turned to the "RUN" position with the driver's safety belt not fastened. The chime will silence as soon as the driver's safety belt is fastened or within six seconds, whichever occurs first. The Seat Belt Indicator will light steady for 20 seconds and then flash for an additional 55 seconds. The indicator will go out as soon as the driver's safety belt is fastened or the light times out, whichever occurs first. Please note that unbuckling the seat belt will result in this sequence repeating. During a loss of serial data (ignition in OFF/UNLOCK"), the telltale will light steady. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Impact Sensor: Recalls Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA98V146000 > Jun > 98 > Recall 98V146000: Air Bag Deploys Inadvertently Impact Sensor: All Technical Service Bulletins Recall 98V146000: Air Bag Deploys Inadvertently Vehicle Description: Passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan. Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them. Dealers will recalibrate the air bag sensing and diagnostic module. Owner notification began during August 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1022 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4326). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 9593 Front Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor Impact Sensor: Service and Repair Front End Discriminating Sensor The presence of an inflatable restraint front end discriminating sensor enhances the SIR system performance. Use of the inflatable restraint front end discriminating sensor provides timely deployment of the air bags during some crashes. Although this is a mechanical sensor, it is not a part of the deployment loop but instead only provides an input signal to the inflatable restraint sensing and diagnostic module. Caution should be used to ensure proper location of sensors to the mounting brackets. The keying of the sensor to the wiring harness connectors must not be modified for any reason. CAUTION: During service procedures, be very careful when handling a sensor. Never strike or jar a sensor. Under some circumstances, it could cause deployment and result in personal injury or improper operation of the Supplemental Inflatable Restraint (SIR) system. All sensors and mounting bracket bolts must be carefully torqued to assure proper operation. Never power up the SIR system when any sensor is not rigidly attached to vehicle, since the sensor could be activated when not attached and could result in deployment. REMOVE OR DISCONNECT ^ Disable the SIR system. Refer to "Disabling the SIR System." See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair 1. The Connector Position Assurance (CPA) and the electrical connector. 2. The sensor mounting fasteners. 3. The sensor from the vehicle. IMPORTANT ^ The following repair procedures should only be used in the event that the sensor mounting holes and/or fasteners are damaged to the extent that the sensor can no longer be properly mounted. 1. Remove and discard the fastener. 2. Chisel off the damaged weld nut. 3. Condition the front end lower tie surface where the new weld nut is to he installed. 4. Install the new weld nut (P/N 11514034) into position. 5. Migweld the new weld nut to the front end lower tie surface in the correct location. 6. Use a new fastener (P/N 11515926). CAUTION: Proper operation of the inflatable restraint Front End Discriminating Sensor requires the sensor be rigidly attached to the vehicle structure and the arrow on the sensor be pointing towards the front of the vehicle. INSTALL OR CONNECT 1. The sensor to the vehicle, make sure the arrow is pointing toward the front of the vehicle. 2. The sensor mounting fasteners. TIGHTEN Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9596 ^ The fasteners to 10 N.m (89 lb in.). 3. The electrical connector and the connector position assurance (CPA). ^ Enable the SIR system. Refer to "Enabling the SIR System." See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front End Discriminating Sensor > Page 9597 Impact Sensor: Service and Repair Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as "the portion of the vehicle which is crushed, bent, or damaged due to a collision." For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has a SIR sensor mounted forward of the radiator, it must be replaced. ^ Replace the sensor whether or not the air bags have deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor Also, if you follow a diagnostic trouble code table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 9620 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 9630 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 9635 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 9640 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions Alarm Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 Alarm Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9653 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9654 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9655 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9656 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9657 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9658 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9659 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9660 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9661 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9662 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9663 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9664 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9665 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9666 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9667 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9668 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9669 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9670 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9672 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9673 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9674 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9675 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9676 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9677 Alarm Module: Electrical Diagrams Refer to Antitheft and Alarm Systems level diagrams. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9678 Alarm Module: Service and Repair Vehicle Theft Deterrent - Controller Learning Diagram Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9679 Vehicle Theft Deterrent - Component Changing Diagram The PASSLOCK System is designed to prevent theft even if various theft deterrent parts are changed. Parts that can no longer be changed without the possibility of going into a tamper mode are: ^ PASSLOCK Lock Cylinder ^ Instrument Panel Cluster (IPC) ^ Powertrain Control Module (PCM) If any of these parts are replaced, the vehicle may start and stall for 10 (ten) minutes (LONG TAMPER MODE). If this occurs, the system MUST go through a LONG TAMPER MODE cycle. During this time, the THEFT TELLTALE will be flashing for the full ten minutes. The IPC and PCM require the full ten minutes to complete a learn cycle. The Ignition Key MUST remain in the "RUN" position until the telltale stops flashing or the cycle will have to be repeated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Module Mounting And Wiring REMOVE OR DISCONNECT 1. Negative battery cable. 2. Open rear compartment. 3. Left inner trim panel. 4. One electrical connector. 5. Remove push pins. 6. Module. INSTALL OR CONNECT 1. Module to rear compartment brace. 2. Push pins to brace. 3. Electrical connector. 4. Rear compartment trim. 5. Close rear compartment. 6. Negative battery cable. 7. Program to match transmitter(s). Refer to "Remote Keyless Entry Module Programming". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation Module Mounting And Wiring The Remote Keyless Entry Module (receiver) is located in the luggage compartment on the left inner wheel house panel. The following information is on the module: ^ GM Part Number ^ Latest Change Level ^ Julian Date Code (4 digits) ^ Manufacturing Location Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair Transmitter Battery Replacement REMOVE OR DISCONNECT 1. Pry cover in groove with dime or small screwdriver. 2. Cover (leave seal in place). 3. One battery. INSTALL OR CONNECT 1. One battery (positive side down) CR2032 (3 volt) or equivalent. 2. Cover (put seal back into position if it came out of position in Step 2 above). 3. Snap cover into place. 4. Resynchronize the transmitter. Refer to Resynchronization. See: Service and Repair/Transmitter Synchronization 5. Check for proper operation. Normal battery life is approximately two years. The batteries should be replaced when the range of the RKE transmitter begins to decrease significantly to less than approximately seven meters (23 feet). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation The THEFT SYSTEM Indicator shows the security state of the vehicle. It is controlled by the IPC. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration Cellular Phone: Technical Service Bulletins OnStar(R)/Cell Phone - Integration Bulletin No.: 01-08-46-004A Date: March 08, 2005 INFORMATION Subject: Vehicle Integration of Cellular Phones and Normal Operating Characteristics Models: 2002 and Prior Passenger Cars and Trucks Supercede: This bulletin is being issued to cancel Corporate Bulletin Number 01-08-46-004. Please discard all copies of Corporate Bulletin Number 01-08-46-004 (Section 08 - Body and Accessories). This bulletin effectively cancels Corporate Bulletin Number 01-08-46-004. OnStar(R) no longer offers cellular phones as part of the OnStar(R) system. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9701 Technical Service Bulletin # 83-96-05 Date: 980701 Radio Telephone/Mobile Radio - Install/Troubleshooting File In Section: 9 - Accessories Bulletin No.: 83-96-05 Date: July, 1998 Subject: Radio Telephone/Mobile Radio (Transceiver) Installation and Troubleshooting Guidelines Models: 1990-99 Passenger Cars and Trucks This bulletin cancels and supercedes bulletin 34-92-12. Please discard Corporate Bulletin Number 34-92-12 (Section 9 - Accessories). The following information is being provided to assist in the installation and troubleshooting of Radio Telephone/Mobile Radios. Certain radio telephones or land mobile radios (also known as Radio Transceivers), or the way in which they are installed, may adversely affect various vehicle operations such as engine performance, driver information, entertainment and electrical systems. Expenses incurred to protect the vehicle systems from any adverse effect of any such installation are NOT the responsibility of General Motors Corporation. The following are general guidelines for installing a radio transceiver in General Motors vehicles. These guidelines are intended to supplement, but not to be used in place of, detailed instructions which are the sole responsibility of the manufacturer of the involved radio transceiver. Although this document refers to passenger vehicles, the same general guidelines apply to trucks. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9702 EMC TROUBLESHOOTING CHART 1. Transceiver Location Refer to the attached figures during installation. 1. Transceiver Location Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9703 a. One piece transceivers should be mounted under the dash, or on the transmission hump where they will not interfere with vehicle controls or passenger movement (See Figure 1 - One Piece Transceiver Installation). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9704 b. Locate the transceiver for remote radios on the driver's side of trunk as near to the vehicle body side as possible (See Figure 2 - Trunk Mount Transceiver Installation). Caution: To avoid possible serious injury, do not mount any transceivers, microphones, speakers, or any other item In the deployment path of a Supplemental Inflatable Restraint (SIR) or "Air Bag". 2. Antenna Installation a. Each vehicle model reacts to radio frequency energy differently. It is suggested that a magnetic-mount antenna be used to check the proposed antenna location for unwanted effects on the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9705 Antenna location is a major factor in these effects. b. The antenna should be a permanent-mount type, located in the center of the roof or center of the rear deck lid. If a magnet-mount antenna is used, care should be taken to mount the antenna in the same location as a permanent-mount type. If a disguise-mount antenna is used, great care should be taken to shield (using copper tape, etc.) any tuning network from vehicle electronics and wiring, or mount the tuning network in an area completely clear (6 inches or 15 cm away) of vehicle electronics and wiring. c. Standard metal mount antennas may be mounted on a vehicle with non-metallic body panels by two methods: 1. Mount the antenna near a metal frame section and bond the antenna mount to the frame with a short metal strap, which will provide the ground plane connection. 2. Some antenna manufacturers may offer "Ground Plane Kits" that consist of self adhesive metal foil that may be attached to the body panel to provide a ground plane connection. d. Glass Mount Antennas Glass mounted antennas should be kept as high as possible in the center of the rear window or windshield, between rear window defrost "grid lines", if present. Some vehicles use glass that contains a thin metallic layer for defrosting, or to control solar gain. GLASS MOUNT ANTENNAS WILL NOT FUNCTION WHEN MOUNTED ON THIS TYPE OF GLASS. 3. Antenna Cable Routing a. Always use high quality coax cable (95% shield coverage minimum), located away (at least 6 inches or 15 cm) from ECM's, PCM's and other electronic modules. b. Care should be taken to maintain as great a distance as possible between any vehicle wiring and coax cable. 4. Antenna Tuning It is important that the antenna be tuned properly and that reflected power be kept to less than 10% (VSWR less than 2:1) at all operating frequencies. Important: High VSWR has been shown to contribute/cause interference problems with vehicle systems. 5. Radio Wiring and Power Lead Connection Locations a. Methods to connect radio power on General Motors vehicles is dependent on the vehicle model (See Figure 1 - One Piece Transceiver Installation or Figure 2 - Trunk Mount Transceiver Installation as needed). Do not connect the negative power lead to any under-dash termination point. One of the following four methods is suggested: 1. Connect the positive and negative power leads directly to the battery terminals. GM approved methods of connecting auxiliary wiring include the adapter package illustrated in Figure 4 - Power Cable Battery Connections. Important: It is recommended that a fuse be placed in the transceiver negative power lead. This is to prevent possible transceiver damage in the event the battery to engine block ground lead is inadvertently disconnected. 2. Connect the positive lead to the auxiliary power terminal (usually identified by a red plastic cover in the underhood area). Connect the negative lead directly to the negative battery terminal. Important: See above important statement regarding fusing the negative power lead. 3. Connect the positive lead to the auxiliary power terminal (usually identified by a red plastic cover in the underhood area). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9706 Connect the negative lead to the battery body connection point (usually identified by a short # 10 AWG or larger wire running from the negative battery terminal to the body of the vehicle). Important: See above important statement regarding fusing the negative power lead. 4. Connect the positive and negative leads to the Special Equipment Option (SEO) wiring provided for this purpose (if vehicle has this option). b. For One Piece Transceivers (See Figure 1 - One Piece Transceiver Installation) When ignition switch control is desired, and no SEO wiring exists, a 12 volt power contactor must be installed in the transceiver positive power lead (See Figure 3 - Power Contactor Wiring). The contactor (supplied by the installer) should be located near a proper 12 volt feed source. One lead of the contactor coil should be connected through an appropriate in-line fuse to an available accessory circuit or ignition circuit not Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > OnStar(R)/Cell Phone - Integration > Page 9707 powered during engine cranking. The return lead of the contactor coil must return to a proper fused negative point. c. Handset or Control Units 1. Any negative power lead from a handset or control unit must return to a properly fused negative connection point. 2. It is preferable that the positive power lead for a handset, or control unit, be connected directly to a properly fused positive power feed point. If ignition switch control is desired, the handset or control unit positive power lead may be connected through an appropriate in-line fuse to an available accessory circuit (or ignition circuit not powered during engine cranking). 3. It is recommended that the handset or control unit positive and negative power leads be appropriately fused separately from the transceiver positive and negative power leads. d. Multiple Transceivers or Receivers If multiple transceivers or receivers are to be installed in the vehicle, power leads to the trunk or under the dash should be connected to covered, insulated terminal strips. All transceivers or receivers may then have their power leads connected to the insulated terminal strips. This makes a neater installation and reduces the number of wires running to the vehicle underhood area. Both positive and negative power leads should be fused. 6. Radio Wire Routing (See Figure 1 - One Piece Transceiver Installation, or Figure 2 - Trunk Mount Transceiver Installation as needed). a. The power leads (fused) should be brought through a grommeted hole (provided by the installer) in the front cowl. For trunk mounted transceivers, the cables should continue on along the driver's side door sills, under the rear seat and into the trunk through a rear bulkhead. Maintain as great a distance as possible between radio power leads and vehicle electronic modules and wiring. b. If the radio power leads need to cross the engine compartment, they should cross between the engine and the front of the vehicle. Troubleshooting Refer to the Troubleshooting Chart as needed. 1. Most vehicle-radio interaction is avoided by following the Installation Guidelines outlined above. 2. If vehicle-radio interaction is evident following radio installation, the source of the problem should be determined prior to further vehicle/radio operation. The EMC Troubleshooting Chart should help in determining the source of the vehicle-radio interaction. Parts Information P/N Description 1846855 Adapter Kit, Side Terminal Battery (consisting of Adapter Terminal, Terminal Cover, Wire Connector, Insulation Boot) 12004188 Bolt, Battery Cable Terminal 12354951 Spacer, Battery Cable Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Emergency Contact Module: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9712 Emergency Contact Module: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9713 Emergency Contact Module: Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 9719 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Navigation System: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9724 Navigation System: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9725 Navigation System: Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 649601 > Jan > 97 > Compact Disc Players - CD Changer Loading Procedures Compact Disc Player (CD): Customer Interest Compact Disc Players - CD Changer Loading Procedures File In Section: 9 - Accessories Bulletin No.: 64-96-01 Date: January, 1997 INFORMATION Subject: Compact Disc Players - Procedures for Correct Use and Maintenance Models: 1997 and Prior Passenger Cars and Trucks CD Changer Loading Procedures Because of differences in CD changer loading procedures, some confusion exists regarding this issue. Although correct loading procedures are included with each changer's Owner's Manual, often this information is not available to the dealer service personnel. Verify proper loading when evaluating customer concerns of "CD inoperative". Delco Electronics Product Type Loading Procedure Radio w/intergral CD label side up 6 disc changer (LLAI) label side up 10 disc changer (FMI) label side up 12 disc changer (LLAI) label side down Important: Failure to load magazine/player correctly will disable the operation. Important: Only the 12 disc changer is to be loaded with the label side down. CD Cleaners Avoid use of commercially available CD cleaners. The use of CD cleaners is not recommended and can damage the player's CD mechanism. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 649601 > Jan > 97 > Compact Disc Players - CD Changer Loading Procedures Compact Disc Player (CD): All Technical Service Bulletins Compact Disc Players - CD Changer Loading Procedures File In Section: 9 - Accessories Bulletin No.: 64-96-01 Date: January, 1997 INFORMATION Subject: Compact Disc Players - Procedures for Correct Use and Maintenance Models: 1997 and Prior Passenger Cars and Trucks CD Changer Loading Procedures Because of differences in CD changer loading procedures, some confusion exists regarding this issue. Although correct loading procedures are included with each changer's Owner's Manual, often this information is not available to the dealer service personnel. Verify proper loading when evaluating customer concerns of "CD inoperative". Delco Electronics Product Type Loading Procedure Radio w/intergral CD label side up 6 disc changer (LLAI) label side up 10 disc changer (FMI) label side up 12 disc changer (LLAI) label side down Important: Failure to load magazine/player correctly will disable the operation. Important: Only the 12 disc changer is to be loaded with the label side down. CD Cleaners Avoid use of commercially available CD cleaners. The use of CD cleaners is not recommended and can damage the player's CD mechanism. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions Compact Disc Player (CD): Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9742 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9743 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9744 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9745 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9746 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9747 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9748 Compact Disc Player (CD): Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9749 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9750 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9751 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9752 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9753 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9754 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9755 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9756 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9757 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9758 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9759 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9760 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9761 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9762 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9763 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9764 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9765 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9766 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9767 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9768 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9769 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9770 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9771 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Diagrams > Diagram Information and Instructions > Page 9772 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits Radio/Stereo: Technical Service Bulletins Instruments - New Diagnostic Tables For VSS Circuits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-81-32 Date: May, 1997 SERVICE MANUAL UPDATE Subject: Section 8A - Electrical Diagnosis - New Diagnostic Tables for Vehicle Speed Sensor Signal Circuit Models: 1996-97 Buick Skylark 1996 Chevrolet Beretta, Corsica 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1997 Oldsmobile Cutlass 1996-97 Pontiac Grand Am, Sunfire This bulletin is being issued to add new diagnostic tables to Section 8A of the Service Manual. The tables included describe the diagnostic procedures for the diagnosis of the Vehicle Speed Sensor signal circuit from the Powertrain Control Module (PCM) to auxiliary devices. Please insert the included diagnostic tables into the Electrical Diagnosis Instrument Cluster section (Cell 80 J/L/N cars; Cell 81 L/N cars) of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9777 8A - 1 - 1 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9778 8A - 1 - 2 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9779 8A - 1 - 3 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9780 8A - 1 - 4 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9781 8A - 1 - 5 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9782 8A - 1 - 6 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9783 8A - 1 - 7 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9784 8A - 1 - 8 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9785 8A - 1 - 9 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9786 8A - 1 - 10 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9787 8A - 1 - 11 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9788 8A - 1 - 12 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9789 8A - 1 - 13 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9790 8A - 1 - 14 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9791 8A - 1 - 15 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9792 8A - 1 - 16 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9793 8A - 1 - 17 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9794 8A - 1 - 18 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9795 8A - 1 - 19 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9796 8A - 1 - 20 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9797 8A - 1 - 21 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9798 8A - 1 - 22 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9799 8A - 1 - 23 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9800 8A - 1 - 24 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9801 8A - 1 - 25 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9802 8A - 1 - 26 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9803 8A - 1 - 27 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9804 8A - 1 - 28 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9805 Radio/Stereo: Technical Service Bulletins Radio Display - Error Code Diagnosis/Repair File In Section: 08 - Body and Accessories Bulletin No.: 01-08-44-005 Date: April, 2001 INFORMATION Subject: Information on Error Codes on Radio Display - Their Cause and Corrective Action Models: 1995 - 1999 Buick LeSabre 1995 - 2002 Buick Century, Park Avenue, Regal 1995 - 1996 Buick Roadmaster 1996 - 1999 Buick Riviera, Skylark 1995 - 1999 Chevrolet Lumina, Monte Carlo 1996 - 1999 Chevrolet Cavalier 1996 Chevrolet Lumina APV 1997 - 2002 Chevrolet Camaro 1998 1999 Chevrolet Venture 1997 - 2002 Chevrolet Corvette 1995 - 1999 Oldsmobile Aurora, Eighty Eight 1995 - 1997 Oldsmobile Cutlass Supreme 1999 - 2000 Oldsmobile Alero 1998 - 2001 Oldsmobile Intrigue 1995 - 1996 Oldsmobile Ninety Eight 1996 - 1999 Oldsmobile Achieva, Silhouette 1996 - 2001 Oldsmobile Bravada 1995 - 1999 Pontiac Bonneville, Sunfire 1995 - 2002 Pontiac Firebird, Grand Prix 1996 - 2000 Pontiac Grand Am 1996 - 1999 Pontiac Trans Sport 1995 - 2002 Chevrolet and GMC C/K, S/T Trucks 1996 - 2002 Chevrolet and GMC M/L Vans 1996 2000 Chevrolet and GMC G Vans This bulletin is being revised to update model years and vehicles. Please discard Corporate Bulletin Number 64-90-04A (Section 9 - Assessories). Starting in 1995, the family style radios, as well as the 12-disc LLAI and 6-disc LLAI (Low Level Audio Interface) changers and the 10-disc FMI (FM Interface) changers, have error codes to help diagnose playback mediums. Some systems will only have an ERR message and no other indicator. If an ERR message is encountered without any other identifier, you may review the following error codes to try to determine the cause of the error and correct it before sending the unit to the authorized service center. If ERR or E (and a number) appears on a customer's radio display, the number may give you a clue to the problem and corrective action. Below is a list of code numbers that may appear on the unit. Important: Not all family radios have these codes. They are dependent on the model year. Cassette Errors - E10: Tight tape error Cause(s): A restricted cassette tape transport or broken cassette drive belt Correction: Substitute a different cassette tape. If there still is an error code, service the unit at an ACDelco(R) Service Center. - E11: Broken Tape Error Cause(s): A broken cassette tape Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9806 Correction(s): Substitute a different cassette tape - E12: Communication Error Cause(s): A vehicle/radio communication problem or an internal radio communication problem. Correction(s): Disconnect the battery voltage to the radio then reconnect after a few minutes. If there still is an error, service the unit at an ACDelco(R) Service Center. - E13: Tape Communication Error Cause(s): The micro-processor is reading the speed pulses from the tape deck either too fast or too slow. Correction(s): It the tape player is still playing a cassette, try a new cassette. If there is still an error, service the unit at an ACDelco(R) Service Center. - E14: Wrapped Tape Cause(s): The tape is wrapped around the capstan. This means a tape is wound up in the tape player. This error message could appear when a CD adapter is being used. Other causes could be old or damaged tapes. Long playing (90 or 120 minute) tapes are thin and can stretch easily creating this condition. Correction(s): Try playing a known good quality tape. Remove the CD adapter. - Cln Tape Indicator Cause(s): This message appears after 50 hours of accumulated tape play. Correction(s): We suggest cleaning the tape head. Then reset the radio by depressing the eject button for five seconds. Cleaning the heads will not reset the "Cln" display. To reset the "Cln" display, push and hold the eject button for five seconds. The display will return to its normal display. CD Errors - E20: Focus Error Cause(s): The CD player cannot focus on the disc or there is an internal focus problem. Correction(s): Try cleaning the disc or using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If the problem is not corrected, service the unit at an ACDelco(R) Service Center. - E21: Tracking Error Cause(s): There is a problem with reading the disc. Correction(s): Try cleaning the disc or using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If there is still an error, service the unit at an ACDelco(R) Service Center. - E22: Motor Error Cause(s): The CD motor is not handling the compact disc properly. Correction(s): Service or exchange the unit at an ACDelco(R) Service Center. - E23: Communications Error Cause(s): There is a vehicle/radio communication problem or an internal radio communication problem. Correction(s): Disconnect battery voltage to the radio and then reconnect after a few minutes. If there is still an error, send the unit to an ACDelco(R) Service Center. LLAI CD Changer Errors - E30: Focus Error Cause(s): The CD player cannot focus on the disc or there is an internal focus problem. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9807 Correction(s): Try cleaning the disc or using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If there is still an error, service the unit at an ACDelco(R) Service Center. - E31: Tracking Error Cause(s): There is a problem with reading the disc. Correction(s): Try cleaning the disc or try using a new disc. Make sure the disc is loaded correctly. The road could be too rough or there is too much humidity. If there is still an error, service the unit at an ACDelco(R) Service Center. - E32: Motor Error Cause(s): The CD motor is not handling the compact disc properly or defective magazine mounting screws are interfering with the mechanism. Correction(s): Reload the magazine. If there is still a problem, replace the magazine. If the problem continues, back out the mounting screws. If the condition is corrected, replace the screws with shorter screws or add washers to the existing screws. If this condition still exists, service the unit at an ACDelco(R) Service Center. - E33: CD Changer Communication Error Cause(s): There is a vehicle/radio communication problem or internal radio communication problem. Correction(s): Disconnect battery voltage to the radio and then reconnect after a few minutes. If there is still an error, determine if the problem is with the radio, the harness or the changer. Inspect for correct voltage at all connectors. If there is still an error, service the unit at an ACDelco(R) Service Center. - E34: Changer Door Open - E35: Changer Magazine Empty FMI 10-Disc Changer Errors - E01 Cause: This indicates a malfunction of the disc changer functions. Correction: Before sending the unit in for service, perform the following procedure: 1. Press the reset button on both the changer and the remote. The reset button on the changer is located on the front panel of the unit. It can be activated with the tip of a pin. 2. If the unit does not operate after resetting it, remove the magazine by inserting a business card between the magazine and the mechanism. The lock lever will disengage to allow the magazine to eject. 3. Make sure all CDs are in the magazine and none remain lodged in the carriage. If, upon removing the magazine, a CD is found lodged in the carriage, remove all CDs from the magazine and reinsert the magazine into the changer. 4. Press the eject button. This should cause the lodged CD to move from the carriage into the empty magazine. The magazine should automatically eject and normal operation will return. 5. If the changer fails to resume normal operation, send the unit to an ACDelco(R) Service Center. - E30 Cause: Excessive temperature Correction: Let the temperature of the changer resume to the normal range. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9808 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9809 Radio/Stereo: Technical Service Bulletins Audio - Procedure To Handle Customer Radio Concerns File In Section: 9 - Accessories Bulletin No.: 68-96-O1A Date: October, 1996 INFORMATION Subject: Procedure to Handle Customer Radio Concerns Models: 1997 and Prior Passenger Cars and Trucks This bulletin is being revised to change the Sales Center Information to Service Center Information. Please discard Corporate Bulletin Number 68-96-01 (Section 9 - Accessories). Many of the radios being returned to the Delco Electronics remanufacturing centers have been misdiagnosed. This misdiagnosis results in unnecessary customer comebacks, decreased customer satisfaction and reduces the availability of exchange radios. To resolve these issues, the following information was developed to give General Motors' dealers a common service process to handle customer audio system concerns. When a customer either calls or comes in with a concern about the radio system in their vehicle, it is important that as much information as possible is gathered. This process begins with the Service Consultant asking the customer specific questions related to their vehicle as outlined on the Service Writer/Customer Check list. Once the Service Consultant has completed the diagnostic worksheet, it should be attached to the customer repair order for the technician. This worksheet should help the technician determine if the concern is vehicle related or radio related. Two excellent service manuals are also available for this purpose and are available from General Motors at the address shown below. A service bulletin, 34-92-12, Radio Frequency Interference Diagnosis, is also available as is assistance from the Divisional Technical Assistance Centers. Mascotech Mktg. Service 1972 Brown Road Auburn Hills, ML 48326 1-800-393-4831 Delco Electronics Sound Service Audio Systems Diagnostic Guide P/N 19007.03-1A @ $10.00 per manual STG Audio Systems Training manual P/N 19007.03-2 @ $15.00 per manual Repairs to the vehicle or the audio system can usually be done very quickly and the vehicle returned to the customer that day. If the diagnosis indicates that the radio needs to be replaced, remove the radio from the vehicle and order an exchange radio from your local AC Delco radio exchange center. There are 28 approved AC Delco exchange centers nationally (listing attached). If your local exchange center does not have the required exchange radio, it is important that you contact the AC Delco locator service. This service can be found on the Service Parts TRACS system 1-800-433-6961, prompt 4. It will be necessary to request overnight shipping so that the owner's vehicle is retained at your dealership for only one night. If the vehicle is kept overnight and it is a warranty repair, the customer should be offered courtesy transportation or alternate transportation. Please do not return the vehicle with the suspect radio installed or without a radio. Many of our vehicles today use a multiplex wiring system and the vehicle will not run correctly without a radio. When you receive the exchange radio, please return the removed radio to the AC Delco Exchange Center within 24 hours (please enclose the diagnostic worksheet that the Service Consultant and the Technician used with the removed radio along with the 1078 form). This will help the AC Delco Exchange Center. In the event you know the vehicle will need a radio before the customer brings the vehicle in, every effort should be made to have a pre-exchanged radio available. A radio identification list is attached to help you select the correct radio. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9810 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9811 AC Delco AUTHORIZED ELECTRONIC SERVICE CENTERS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9812 Duplicate form for your convenience SERVICE WRITER/CUSTOMER CHECK LIST Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9813 RECEPTION/NOISE CONCERN: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9814 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9815 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9816 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9817 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9818 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9819 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Instruments - New Diagnostic Tables For VSS Circuits > Page 9820 1997 APPLICATIONS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations > Component Locations Radio/Stereo: Component Locations LH Rear Of Passenger Compartment Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations > Component Locations > Page 9823 RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9826 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9827 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9828 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9829 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9830 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9831 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9832 Radio/Stereo: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9833 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9834 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9835 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9836 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9837 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9838 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9839 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9840 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9841 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9842 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9843 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9844 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9845 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9846 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9847 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9848 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9849 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9850 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9851 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9852 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9853 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9854 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9855 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9856 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9857 Radio/Stereo: Connector Views Radio: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 9858 Radio: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 9859 Radio/Stereo: Service and Repair Description Remove or Disconnect 1. Disable SIR system. 2. Negative battery cable. 3. I/P cluster trim plate. 4. Screws and pull rearward. 5. Electrical and antenna lead connections. Install or Connect 1. Electrical and antenna lead connections. 2. Screws to I/P. 3. I/P cluster trim plate. 4. Negative battery cable. 5. Enable SIR system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations Speaker: Locations LH And RH Top Of Rear Wheel Wells LH Front Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions Speaker: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9865 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9866 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9867 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9868 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9869 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9870 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9871 Speaker: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9872 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9873 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9874 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9875 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9876 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9877 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9878 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9879 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9880 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9881 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9882 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9883 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9884 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9885 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9886 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9887 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9888 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9889 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9890 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9891 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9892 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9893 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9894 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9895 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 549001A > Mar > 97 > Radio CLN Indicator ON Tape Player: Customer Interest Radio - CLN Indicator ON File In Section: 9 - Accessories Bulletin No.: 54-90-01A Date: March, 1997 Subject: "CLN" Indicator Appears On Radio Display and Does Not Turn Off (Reset "CLN" Indicator with the Eject Button On Tape) Models: 1995-96 Buick Roadmaster 1995-97 Buick Regal, Park Avenue, LeSabre 1996-97 Buick Skylark, Riviera 1996-97 Cadillac Eldorado, Seville, Concours 1994-97 Chevrolet Lumina 1995-97 Chevrolet Monte Carlo 1996-97 Chevrolet Cavalier, Lumina Apv 1997 Chevrolet Corvette 1994-97 Oldsmobile Regency, Eighty-Eight 1995-97 Oldsmobile Cutlass Supreme 1995-97 Oldsmobile Aurora 1996-97 Oldsmobile Achieva 1997 Oldsmobile Silhouette 1994-97 Pontiac Grand Prix, Bonneville, Firebird 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am, Trans Sport 1995-97 Chevrolet and GMC C/K Models 1996.5-97 Chevrolet and GMC M/L, G Models This bulletin is being revised to include current model year and additional models. Also included is the procedure for the remote cassette unit. Condition Some owners may comment that "CLN" appears on radio display and does not turn off after tape heads have been cleaned. Cause The "CLN" display is a reminder for the customer that the tape heads need to be cleaned. This reminder will appear after 50 hours of tape usage. The "CLN" indicator will not automatically turn off after the tape heads have been cleaned. Correction Integral Cassette Radios The customer must reset the "CLN" indicator manually. To reset after proper cleaning of the tape heads push the EJECT button and hold for 5 seconds until the display clears. The "CLN" reminder will be reset and start timing the hours of tape usage. The radio display will resume its normal operating functions. Remote Cassette Unit The customer must reset the "CLN" indicator manually. To reset after proper cleaning of the tape heads push the EJECT button on the remote and the RECALL button on the radio and hold for 5 seconds until the display clears. The "CLN" reminder will be reset and start timing the hours of tape usage. The radio display will resume its normal operating functions. Important: Radio and playback functions are discussed in Section 9A of the Service Manuals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 549001A > Mar > 97 > Radio - CLN Indicator ON Tape Player: All Technical Service Bulletins Radio - CLN Indicator ON File In Section: 9 - Accessories Bulletin No.: 54-90-01A Date: March, 1997 Subject: "CLN" Indicator Appears On Radio Display and Does Not Turn Off (Reset "CLN" Indicator with the Eject Button On Tape) Models: 1995-96 Buick Roadmaster 1995-97 Buick Regal, Park Avenue, LeSabre 1996-97 Buick Skylark, Riviera 1996-97 Cadillac Eldorado, Seville, Concours 1994-97 Chevrolet Lumina 1995-97 Chevrolet Monte Carlo 1996-97 Chevrolet Cavalier, Lumina Apv 1997 Chevrolet Corvette 1994-97 Oldsmobile Regency, Eighty-Eight 1995-97 Oldsmobile Cutlass Supreme 1995-97 Oldsmobile Aurora 1996-97 Oldsmobile Achieva 1997 Oldsmobile Silhouette 1994-97 Pontiac Grand Prix, Bonneville, Firebird 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am, Trans Sport 1995-97 Chevrolet and GMC C/K Models 1996.5-97 Chevrolet and GMC M/L, G Models This bulletin is being revised to include current model year and additional models. Also included is the procedure for the remote cassette unit. Condition Some owners may comment that "CLN" appears on radio display and does not turn off after tape heads have been cleaned. Cause The "CLN" display is a reminder for the customer that the tape heads need to be cleaned. This reminder will appear after 50 hours of tape usage. The "CLN" indicator will not automatically turn off after the tape heads have been cleaned. Correction Integral Cassette Radios The customer must reset the "CLN" indicator manually. To reset after proper cleaning of the tape heads push the EJECT button and hold for 5 seconds until the display clears. The "CLN" reminder will be reset and start timing the hours of tape usage. The radio display will resume its normal operating functions. Remote Cassette Unit The customer must reset the "CLN" indicator manually. To reset after proper cleaning of the tape heads push the EJECT button on the remote and the RECALL button on the radio and hold for 5 seconds until the display clears. The "CLN" reminder will be reset and start timing the hours of tape usage. The radio display will resume its normal operating functions. Important: Radio and playback functions are discussed in Section 9A of the Service Manuals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions Tape Player: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9911 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9912 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9913 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9914 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9915 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9916 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9917 Tape Player: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9918 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9919 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9920 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9921 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9922 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9923 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9924 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9925 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9926 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9927 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9928 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9929 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9930 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9931 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9932 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9933 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9934 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9935 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9936 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9937 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9938 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9939 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9940 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 9941 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions Alarm Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9947 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9948 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9949 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9950 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9951 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9952 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9953 Alarm Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9954 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9955 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9956 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9957 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9958 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9959 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9960 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9961 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9962 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9963 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9964 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9965 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9966 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9967 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9968 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9969 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9970 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9971 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9972 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9973 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9974 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9975 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9976 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9977 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Diagram Information and Instructions > Page 9978 Alarm Module: Electrical Diagrams Refer to Antitheft and Alarm Systems level diagrams. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9979 Alarm Module: Service and Repair Vehicle Theft Deterrent - Controller Learning Diagram Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9980 Vehicle Theft Deterrent - Component Changing Diagram The PASSLOCK System is designed to prevent theft even if various theft deterrent parts are changed. Parts that can no longer be changed without the possibility of going into a tamper mode are: ^ PASSLOCK Lock Cylinder ^ Instrument Panel Cluster (IPC) ^ Powertrain Control Module (PCM) If any of these parts are replaced, the vehicle may start and stall for 10 (ten) minutes (LONG TAMPER MODE). If this occurs, the system MUST go through a LONG TAMPER MODE cycle. During this time, the THEFT TELLTALE will be flashing for the full ten minutes. The IPC and PCM require the full ten minutes to complete a learn cycle. The Ignition Key MUST remain in the "RUN" position until the telltale stops flashing or the cycle will have to be repeated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information Emergency Contact Module: Technical Service Bulletins OnStar(R) - Analog Only Systems Information INFORMATION Bulletin No.: 06-08-64-007A Date: September 22, 2008 Subject: Information on OnStar(R) Analog-Only Systems Models Supercede: This bulletin is being revised to update the models affected list above. Please discard Corporate Bulletin Number 06-08-46-007 (Section 08 - Body & Accessories). All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog / Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9985 Emergency Contact Module: Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Analog Only Systems Information > Page 9986 Emergency Contact Module: Technical Service Bulletins OnStar - Analog-Only Systems Information Bulletin No.: 06-08-46-007 Date: December 13, 2006 INFORMATION Subject: Information on OnStar(R) Analog-Only Systems Models: 1996-2001 GM Passenger Cars and Trucks Plus: 2002 Buick LeSabre, Rendezvous 2002-2003 Buick Century, Regal 2002-2005 Buick Park Avenue 2002 Cadillac Eldorado, Escalade Models 2002 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Venture 2002 GMC Denali, Denali XL, Jimmy, Sierra, Yukon, Yukon XL 2002 Oldsmobile Intrigue, Silhouette 2002-2003 Oldsmobile Aurora 2002 Pontiac Aztek, Bonneville, Montana 2002-2003 Pontiac Grand Prix with OnStar(R) (RPO UE1) All vehicles equipped with OnStar(R) listed in this bulletin were built with Analog-Only OnStar(R) Hardware. OnStar(R) equipped vehicles with analog-only equipment were designed to operate only on the analog wireless network and cannot be upgraded for digital network compatibility. Vehicles with this equipment will no longer be able to receive OnStar(R) services beginning January 1, 2008. At that time, service will be available only through Dual-Mode (Analog/Digital) equipment. Analog-Only vehicles cannot be upgraded to digital equipment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Module Mounting And Wiring REMOVE OR DISCONNECT 1. Negative battery cable. 2. Open rear compartment. 3. Left inner trim panel. 4. One electrical connector. 5. Remove push pins. 6. Module. INSTALL OR CONNECT 1. Module to rear compartment brace. 2. Push pins to brace. 3. Electrical connector. 4. Rear compartment trim. 5. Close rear compartment. 6. Negative battery cable. 7. Program to match transmitter(s). Refer to "Remote Keyless Entry Module Programming". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9998 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9999 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10000 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10006 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10007 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10008 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10017 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10018 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10019 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 10025 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 10026 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 10027 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 10037 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 10038 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 10039 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 10040 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 10041 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 10042 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 10050 LH Front Fascia (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 10060 LH Rear Fascia (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair REMOVAL PROCEDURE 1. Lift the front door outside handle (1). 2. Remove the rivets (2) from the front door outside handle. 3. Remove the rod from the front door outside handle (1). 4. Remove the front door outside handle (1). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 10072 1. Install the rod to the front door outside handle (1). 2. Install the front door outside handle (1). 3. Lift the front door outside handle (1). 4. Install the rivets (2) to the front door outside handle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 00-08-49-003 > Jun > 00 > Instrument Panel Rattle or Squeak/Door Panel Scratched Front Door Panel: Customer Interest Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 00-08-49-003 > Jun > 00 > Instrument Panel Rattle or Squeak/Door Panel Scratched > Page 10081 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 00-08-49-003 > Jun > 00 > Instrument Panel Rattle or Squeak/Door Panel Scratched > Page 10082 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 00-08-49-003 > Jun > 00 > Instrument Panel Rattle or Squeak/Door Panel Scratched > Page 10083 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched Front Door Panel: All Technical Service Bulletins Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 10089 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 10090 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 00-08-49-003 > Jun > 00 > Instrument Panel - Rattle or Squeak/Door Panel Scratched > Page 10091 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10097 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10098 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10103 Front Door Panel: By Symptom Technical Service Bulletin # 00-08-49-003 Date: 000601 Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10104 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10105 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10106 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 00-08-49-003 Date: 000601 Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10107 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10108 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10109 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 00-08-49-003 Date: 000601 Instrument Panel - Rattle or Squeak/Door Panel Scratched File In Section: 08 - Body and Accessories Bulletin No.: 00-05-49-003 Date: June, 2000 TECHNICAL Subject: Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire Condition Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice: Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10110 Remove the instrument panel and align the tie bar (3) to the body sheet metal (4) using the following procedure. The illustration shows the tie bar when INCORRECTLY aligned (1) and when CORRECTLY aligned (2). When correctly aligned (2), the hole in the body sheet metal is centered in the middle of the notch in the tie bar bracket. For additional information on cautions, instrument panel removal, installation, fasteners and torque specifications, see the Instrument Panel, Gauges and Console sub-section of Body and Accessories in the appropriate Service Manual. 1. Disconnect the negative battery cable. 2. Disable the SIR system. 3. Remove the defroster grille. 4. Remove the instrument panel end panels. 5 Remove the instrument panel valance (Sunfire only). 6. Open the instrument panel storage compartment and remove the accessory trim plate (Sunfire only). 7. Remove the storage compartment trim plate with compartment lamp (Sunfire only). 8. Remove the instrument panel cluster trim plate (Cavalier only). 9. Remove the instrument panel trim pad. 10. Remove the HVAC control. 11. Remove the radio. 12. Remove the air distribution duct. 13. Remove the tilt lever. 14. Remove the steering column covers. 15. Remove the driver's side SIR inflator module. 16. Remove the steering wheel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10111 17. Remove the instrument panel cluster assembly. 18. Remove the defroster duct. 19. Remove the passenger side SIR inflator module. 20. Remove the multi-function switch/lever. 21. Remove the windshield wiper washer lever. 22. Remove the lower instrument panel assembly from the vehicle. 23. Loosen the upper steering column attaching bolts. 24. Remove the lower heater duct trim covers. 25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners. 26. Install the lower heater duct trim covers. 27. Tighten the upper steering column attaching bolts. 28. Install the lower instrument panel assembly to the vehicle. 29. Install the windshield wiper washer lever. 30. Install the multi-function switch/lever. 31. Install the passenger side SIR inflator module. 32. Install the defroster duct. 33. Install the instrument panel cluster assembly. 34. Install the steering wheel. 35 Install the driver's side SIR inflator module. 36. Install the steering column covers. 37. Install the tilt lever. 38. Install the air distribution duct. 39. Install the radio. 40. Install the HVAC control. 41. Install the instrument panel trim pad. 42. Install the instrument panel cluster trim plate (Cavalier only). 43. Install the storage compartment trim plate with compartment lamp (Sunfire only). 44. Install the accessory trim plate and close the storage compartment door (Sunfire only). 45. Install the instrument panel valance (Sunfire only). 46. Install the instrument panel end panels. 47. Install the defroster grille. 48. Enable the SIR system. 49. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 10112 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Trim Panel Replacement Front Door Panel: Service and Repair Door Trim Panel Replacement DOOR TRIM PANEL Front Door Trim Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Trim Panel Replacement > Page 10115 Rear Door Trim Panel TOOLS REQUIRED: ^ J 24595-C Door Trim Pad Remover REMOVE OR DISCONNECT 1. Power door lock switch. 2. Power window switch. 3. Door window regulator handle. 4. Front door upper trim finish panel. 5. Door trim panel lower screws. 6. Door arm rest screws. 7. (Sedan front and coupe only) Door trim clips at sealing strip. 8. Door trim panel fasteners from door inner panel using tool J 24595-C. 9. Door trim panel. INSTALL OR CONNECT 1. Push door trim panel to engage fasteners. 2. (Sedan front and coupe only) Push door trim panel outward and downward at sealing strip to engage clips to door inner. 3. Door arm rest screws. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Trim Panel Replacement > Page 10116 TIGHTEN ^ Screw to 1.5 Nm (13.3 lb. in.). 4. Door trim panel lower screws. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.). 5. Front door upper trim finish panel. 6. Door window regulator handle. 7. Power window switch. 8. Power door lock switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Door Trim Panel Replacement > Page 10117 Front Door Panel: Service and Repair Front Door Upper Trim Finish Panel FRONT DOOR UPPER TRIM FINISH PANEL Front Door Upper Trim Finish Panel REMOVE OR DISCONNECT 1. Front door upper trim finish panel screw. 2. Power mirror switch. 3. Front door upper trim finish panel. INSTALL OR CONNECT 1. Power mirror switch to front door upper trim finish panel. 2. Front door upper trim finish panel. 3. Front door upper trim finish panel screw. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 10122 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 10123 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Locations Front Center Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Customer Interest: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch: Customer Interest Rear Compartment Lid Latch - Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Customer Interest: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 10137 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation Trunk / Liftgate Latch: All Technical Service Bulletins Trap Resistant Trunk Kit Function/Installation File In Section: 08 - Body and Accessories Bulletin No.: 99-08-66-002A Date: January, 2000 Subject: Trap Resistant Rear Compartment (Trunk) Kit Models: 1990-2000 Passenger Cars with Rear Compartments Except: 1990-1991 Buick Reatta 2000 Buick LeSabre 1990-1993 Cadillac Allante, Fleetwood Brougham 1997-2000 Cadillac Seville 2000 Cadillac Deville 1990 Chevrolet Caprice 1990-1991 Chevrolet Cavalier 1990-1996 Chevrolet Beretta 1990-2000 Chevrolet Metro, Prizm 1998-2000 Chevrolet Corvette 2000 Chevrolet Impala 1990-1992 Oldsmobile Toronado/Trofeo 1990-1991 Pontiac Sunbird 1990-1993 Pontiac LeMans 2000 Pontiac Bonneville This bulletin is being revised to add additional models and new part numbers. Please discard Corporate Bulletin Number 99-O8-66-002 (Section 08 - Body and Accessories). The purpose of this bulletin is to inform dealership personnel about the Trap Resistant Rear Compartment (Trunk) Kit, including the system function, necessary vehicle modifications and part numbers required to install the kit. The Trap Resistant Rear Compartment kit is composed of three main system components; one of which (the Rear Seat Tether), may or may not be needed, depending on the vehicle being retrofit. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation > Page 10143 The first component of the kit is the illuminated Interior Release Handle (1). The Release Handle is mounted inside the rear compartment to the deck lid. This handle was designed so that a small child trapped in the rear compartment could use it to open the deck lid. The handle operates the deck lid latch mechanically, but is illuminated with two LED's when the deck lid is closed. The handle remains illuminated for a period of about one hour after the deck lid is closed. The LED's create a small parasitic load that will not drain the vehicle battery with normal usage. The second component of the kit is the Trap Resistant Latch (2). the Trap Resistant Latch is a modified deck lid latch designed to help prevent a child from unintentionally closing and latching the deck lid. The Trap Resistant Latch opens the rear compartment normally through all current means (key, RKE or passenger compartment release) but cannot be re-latched without the user performing a reset function. This reset function consists of pushing up on a small knob (3), while simultaneously pushing a slide mechanism to the right (4). Once the slide mechanism is fully pushed over, the small knob can be released. This function is a simple on-hand operation for an adult, but is difficult for a young child to perform. If the latch is not enabled, the deck lid will not latch and the rear compartment will not close. The third component is the Rear Seat Tether Kit. If the vehicle is equipped with a pass-through to the rear compartment and the folding rear seat can be unlatched from within the passenger compartment without the use of a key or other unlocking feature, then a Rear Seat Tether must be installed. This tether helps prevent a child from gaining access to the rear compartment of a vehicle from the passenger compartment by allowing a secondary lock of the seatback. The Rear Seat Tether employs one or two tethers (one per folding seatback), each permanently connected to a T-handle anchor mounted in the rear compartment. To lock the folding seatback, the user can partially fold the seatback and attach the tether to another T-handle anchor mounted to the seatback. When the tether is affixed to both T-handle anchors, the seat cannot be folded down. To fold down the seatback, the tether must be removed from the anchor attached to the seatback. Important: Installation of the Trap Resistant Latch on some vehicles may require sheet metal and/or trim modifications to the rear compartment striker area. These modifications should be communicated with the customer prior to installations. Also, installation of the Trap Resistant Latch requires a rear compartment lid "ajar" switch. Prior to ordering the Trap Resistant Rear Compartment Kit, inspect the old deck lid latch to see if it is equipped with an "ajar" switch. If the vehicle is not equipped with this switch, P/N 12506174 must be ordered. After completing the Trap Resistant Rear Compartment Kit installation, provide the customer with the supplemental Owner's Manual insert included in the kit and demonstrate the system function. This program is specially structured for a single purchase price to the owner. The owner is responsible to pay a maximum of $50.00 U.S.; $80.00 Canadian for parts and labor to install the complete Trap Resistant Rear Compartment Kit and Rear Seat Tether(s), if required. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-66-002A > Jan > 00 > Trap Resistant Trunk Kit - Function/Installation > Page 10144 Parts are currently available from GMSPO. Labor Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch: All Technical Service Bulletins Rear Compartment Lid Latch - Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 10149 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-15 > Aug > 98 > Rear Lid Latch - Revised Procedure for Replacement Trunk / Liftgate Latch: All Technical Service Bulletins Rear Lid Latch - Revised Procedure for Replacement File In Section: 10 - Body Bulletin No.: 83-15-15 Date: August, 1998 SERVICE MANUAL UPDATE Subject: Section 10-8 - Revised Remove and Install Procedure for Rear Compartment Lid Latch Assembly to Add Spacer Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to revise the remove and install procedure for rear compartment lid latch assembly (to add spacer for convertible only) in Section 10-8 of the Service Manual. Rear compartment Lid Latch Assembly Remove or Disconnect 1. Rear compartment lid latch cable assembly. 2. Unclip cable door at top of rear compartment lock release box. 3. Rear compartment lid remote release cable from lock release box. 4. Rear compartment lid latch assembly bolts. 5. Rear compartment lid latch assembly. 6. Rear compartment lid latch assembly spacer (convertible only). Install or Connect 1. Rear compartment lid latch assembly spacer (convertible only). 2. Rear compartment lid latch assembly. 3. Rear compartment lid latch assembly bolts. 4. Rear compartment lid remote release cable to lock release box. 5. Clip cable door at top of rear compartment lock release box. 6. Rear compartment lid latch cable assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Latch: > NHTSA97V106000 > Jun > 97 > Recall 97V106000: Compact Spare Tire Rim Replacement Spare Tire: All Technical Service Bulletins Recall 97V106000: Compact Spare Tire Rim Replacement The compact spare tire assemblies were assembled with incorrect rims. If the spare tire is underinflated, the bead can separate from the rim causing a rapid loss of air. This does not comply with the requirements of FMVSS No. 110, "Tire Selection and Rims." A rapid loss of air can increase the risk of a vehicle crash. Dealers will replace the rim on the compact spare tire assembly. Owners are requested not to use the spare tire until the rim has been replaced. Owner Notification: Owner notification will begin during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER 1997 PONTIAC SUNFIRE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch Release Cable: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch Release Cable: Customer Interest Rear Compartment Lid Latch - Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch Release Cable: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 10172 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch Release Cable: > 73-15-08 > Oct > 97 > Trunk - Will Not Open When Using Remote Release Handle Trunk / Liftgate Latch Release Cable: Customer Interest Trunk - Will Not Open When Using Remote Release Handle File In Section: 10 - Body Bulletin No.: 73-15-08 Date: October, 1997 Subject: Deck Lid will not Open when Using Interior Remote Release Handle (Replace Rear Compartment Lid Remote Release Cable) Models: 1995-97 Chevrolet Cavalier (with A59 Option) 1995-97 Pontiac Sunfire (with A59 Option) Condition Some owners may comment that the deck lid will not open when the interior remote release handle is pulled. Also, deck lid may not close after being opened by above method. Cause Key cylinder cable box housing walls may flex, which allows the orange slide bar to bind within that housing. Correction Replace the rear compartment lid remote release cable. Refer to the Service Manual for remove and install procedures. Parts Information Old P/N New P/N 22605517 22606550 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time B5470 To Replace Rear Compartment Lid Release 0.6 hr Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch Release Cable: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open Trunk / Liftgate Latch Release Cable: All Technical Service Bulletins Rear Compartment Lid Latch Difficult to Unlock/Open File In Section: 10 - Body Bulletin No.: 83-15-22 Date: December, 1998 Subject: Rear Compartment (Trunk) Lid Latch Difficult to Unlock/Open (Inspect/Replace Cable and Secure with Strap) Models: 1995-99 Chevrolet Cavalier 1995-99 Pontiac Sunfire without RPO AUO (Remote Keyless Entry System) Condition Some customers may comment that the rear compartment (trunk) lid is difficult to unlock with the key. Cause The tab on the cable assembly that secures it to the latch assembly may have broken. When this occurs, the cable may disengage from the latch. Correction Using the following procedure, inspect the tab on the cable assembly for signs of breakage. Replace the cable assembly if the tab is broken. If the tab is not broken, reinstall the cable to the latch. Secure the cable to the latch assembly with plastic strap. Service Procedure 1. Open the rear compartment lid to access the latch on the inside. 2. Remove the fastener securing the cable to the latch (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch Release Cable: > 83-15-22 > Dec > 98 > Rear Compartment Lid Latch - Difficult to Unlock/Open > Page 10182 3. Inspect the tab on the backside of the cable for signs of breakage (see Figure 2). ^ If the tab has NOT disengaged from the latch after removing the fastener, the tab is in acceptable condition and it is NOT necessary to replace the cable assembly. Reinstall the fastener that secures the cable assembly to the latch. ^ If the tab HAS disengaged from the latch after removing the fastener, the tab is broken and the cable assembly must be replaced with a new cable, P/N 22606550. See the appropriate Service Manual for information on replacing the cable assembly. 4. Using one (1) plastic strap, P/N 12355066, secure the cable portion of the assembly to the latch as shown in Figure 1. 5. Trim off excess strap material. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch Release Cable: > 73-15-08 > Oct > 97 > Trunk - Will Not Open When Using Remote Release Handle Trunk / Liftgate Latch Release Cable: All Technical Service Bulletins Trunk - Will Not Open When Using Remote Release Handle File In Section: 10 - Body Bulletin No.: 73-15-08 Date: October, 1997 Subject: Deck Lid will not Open when Using Interior Remote Release Handle (Replace Rear Compartment Lid Remote Release Cable) Models: 1995-97 Chevrolet Cavalier (with A59 Option) 1995-97 Pontiac Sunfire (with A59 Option) Condition Some owners may comment that the deck lid will not open when the interior remote release handle is pulled. Also, deck lid may not close after being opened by above method. Cause Key cylinder cable box housing walls may flex, which allows the orange slide bar to bind within that housing. Correction Replace the rear compartment lid remote release cable. Refer to the Service Manual for remove and install procedures. Parts Information Old P/N New P/N 22605517 22606550 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time B5470 To Replace Rear Compartment Lid Release 0.6 hr Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Release Lever: > 73-15-08 > Oct > 97 > Trunk - Will Not Open When Using Remote Release Handle Trunk / Liftgate Release Lever: Customer Interest Trunk - Will Not Open When Using Remote Release Handle File In Section: 10 - Body Bulletin No.: 73-15-08 Date: October, 1997 Subject: Deck Lid will not Open when Using Interior Remote Release Handle (Replace Rear Compartment Lid Remote Release Cable) Models: 1995-97 Chevrolet Cavalier (with A59 Option) 1995-97 Pontiac Sunfire (with A59 Option) Condition Some owners may comment that the deck lid will not open when the interior remote release handle is pulled. Also, deck lid may not close after being opened by above method. Cause Key cylinder cable box housing walls may flex, which allows the orange slide bar to bind within that housing. Correction Replace the rear compartment lid remote release cable. Refer to the Service Manual for remove and install procedures. Parts Information Old P/N New P/N 22605517 22606550 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time B5470 To Replace Rear Compartment Lid Release 0.6 hr Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Release Lever: > 73-15-08 > Oct > 97 > Trunk - Will Not Open When Using Remote Release Handle Trunk / Liftgate Release Lever: All Technical Service Bulletins Trunk - Will Not Open When Using Remote Release Handle File In Section: 10 - Body Bulletin No.: 73-15-08 Date: October, 1997 Subject: Deck Lid will not Open when Using Interior Remote Release Handle (Replace Rear Compartment Lid Remote Release Cable) Models: 1995-97 Chevrolet Cavalier (with A59 Option) 1995-97 Pontiac Sunfire (with A59 Option) Condition Some owners may comment that the deck lid will not open when the interior remote release handle is pulled. Also, deck lid may not close after being opened by above method. Cause Key cylinder cable box housing walls may flex, which allows the orange slide bar to bind within that housing. Correction Replace the rear compartment lid remote release cable. Refer to the Service Manual for remove and install procedures. Parts Information Old P/N New P/N 22605517 22606550 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time B5470 To Replace Rear Compartment Lid Release 0.6 hr Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Rear Deck Lid Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > Recalls: > NHTSA98V032000 > Feb > 98 > Recall 97V032000: Rocker Panel Welds Fender: Recalls Recall 97V032000: Rocker Panel Welds Year: 1997 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 8 Summary: Vehicle Description: Passenger vehicles. These vehicles were built with mis-located welds at the joint between the left rocker panel inner reinforcement and the body side ring. This does not meet the requirements of FMVSS No. 214, "Side Door Strength." In the event of a vehicle crash, the sheet metal structure would not perform as desired increasing the risk of personal injury. Dealers will inspect the welds and, if necessary, place five welds between the involved panels and apply primer and topcoat finish materials. Owner notification is expected to begin during March 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA98V032000 > Feb > 98 > Recall 97V032000: Rocker Panel Welds Fender: All Technical Service Bulletins Recall 97V032000: Rocker Panel Welds Year: 1997 Make: CHEVROLET, PONTIAC Model: CAVALIER, SUNFIRE Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 8 Summary: Vehicle Description: Passenger vehicles. These vehicles were built with mis-located welds at the joint between the left rocker panel inner reinforcement and the body side ring. This does not meet the requirements of FMVSS No. 214, "Side Door Strength." In the event of a vehicle crash, the sheet metal structure would not perform as desired increasing the risk of personal injury. Dealers will inspect the welds and, if necessary, place five welds between the involved panels and apply primer and topcoat finish materials. Owner notification is expected to begin during March 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fender: > NHTSA98V319000 > Dec > 98 > Recall 98V319000: Suspension Trailing Arm Bolt Defect Trailing Arm: All Technical Service Bulletins Recall 98V319000: Suspension Trailing Arm Bolt Defect Vehicle Description: Passenger vehicles. One of the rear suspension trailing arm bolts can fatigue and break. If this were to occur while the vehicle was in motion, a loss of vehicle control can occur, increasing the risk of a crash. Dealers will replace the rear suspension trailing arm fasteners. Owner notification began December 28, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020 or Pontiac at 1-800-762-2737. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > Page 10231 LH Front Fender (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Suspension (Front) - Torque Specification Update Cross-Member: Technical Service Bulletins Suspension (Front) - Torque Specification Update File In Section: 03 - Suspension Bulletin No.: 02-03-08-006 Date: May, 2002 SERVICE MANUAL UPDATE Subject: Revised Front Suspension Fastener Tightening Specifications Models: 1997-2002 Chevrolet Cavalier 1997-2002 Pontiac Sunfire This bulletin is being issued to revise the fastener tightening specifications in the Lower Control Arm Replacement Procedure and the Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following tightening specification has been revised: Control Arm to Crossmember Bolts (Front Bushing) - 100 N.m plus 90 degrees rotation (74 lb ft). DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Page 10237 Cross-Member: Service and Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Page 10238 ^ Tool Required: J 38892 Ball Joint Separator - Or Equivalent REMOVE OR DISCONNECT 1. Raise vehicle. 2. If suspension contact hoist is used: ^ Place jack stands under uni-body frame near crossmember. ^ Lower vehicle slightly so weight of vehicle rests on the under uni-body frame and not on the control arms or crossmember. 3. Tire and wheel assembly. 4. Right and Left wiring baronesses from crossmember. 5. Ball joint from knuckle using J 38892. NOTICE: Use only the recommended tool for separating the ball joint from knuckle. Failure to use the recommended tool may cause damage to the ball joint and seal. 6. Engine strut to crossmember. 7. Crossmember support braces. 8. Front exhaust pipe, (support catalytic converter). 9. Power steering gear bolts, (support power steering gear). 10. Brake lines from retainers on crossmember. 11. Splash shield from crossmember. 12. Stabilizer bar from crossmember. 13. Crossmember. 14. Control arms from crossmember. INSTALL OR CONNECT 1. Control arms to crossmember and snug bolts only. 2. Crossmember and snug all bolts lightly. 3. Tighten bolts in sequence shown below. ^ Tighten: Crossmember Support Left Rear Outboard Bolt 110 Nm (71 ft. lbs.) plus 90° rotation. - Crossmember Support Right Rear Outboard Bolt 110 Nm (71 ft. lbs.) plus 90° rotation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Page 10239 - Crossmember Support Upper Front Bolts 110 Nm (71 ft. lbs.) plus 90° rotation. - Crossmember Support Rear Inboard Bolts 110 Nm (71 ft. lbs.) plus 90° rotation. 4. Nut attaching ball joint to steering knuckle. Tighten to specifications. ^ Tighten ball joint to steering knuckle nut to 55 Nm (41 ft. lbs.) minimum, 65 Nm (50 ft. lbs.) maximum. Important: Do not loosen nut any time during installation. 5. Power steering gear bolts, hand start bolts and nuts. Tighten left side bolt and nuts to specification first, then tighten right side bolt and nut to specification. 6. Front exhaust pipe. 7. Crossmember support braces. ^ Tighten crossmember braces to core support bolts 72 Nm (53 ft. lbs.). 8. Engine strut to crossmember. 9. Stabilizer bar to crossmember. ^ Tighten stabilizer shaft to support assembly bolts to 66 Nm (49 ft. lbs.). 10. Splash shield to crossmember. 11. Brake lines to retainers to crossmember. 12. Right and Left wiring harenesses to crossmember. 13. Slightly raise vehicle. 14. Remove jack stands from under crossmember. 15. Tire and wheel assembly. 16. With vehicle at curb height, tighten control arm attaching bolts to specifications. ^ Tighten: Control Arm to Crossmember Bolts (Front Bushing) 120 Nm (89 ft. lbs.) plus 180° rotation - Control Arm to Crossmember Bolts (Rear Vertical Bushing) 170 Nm (125 ft. lbs.) 17. Check front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet Carpet: Customer Interest Interior - Rear Footwell Wet File In Section: 08 - Body and Accessories Bulletin No.: 99-08-65-001 Date: March, 1999 TECHNICAL Subject: Rear Footwell Wet (Insert Drain Path) Models: 1995-98 Chevrolet Cavalier Convertible Only 1995-98 Pontiac Sunfire Convertible Only Condition Some customers may comment that the rear floor is wet. Cause When the vehicle is parked nose down on a steep incline, during a hard or prolonged rain, water may accumulate in the front seat belt retractor area. This could result in flooding over the poured-in-place foam and then into the passenger compartment. Correction Add the drain path, using the following procedure: 1. Remove the RH and LH rear quarter trim panels. 2. Remove the RH and LH lower seat belt retractor bolts and set the retractor aside. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet > Page 10249 3. See the figure for approximate locations for the 10 mm (3/8 in.) drain holes in the foam. Hole location is critical. 4. Install a drill stop placed approximately 32 mm (1-1/4 in.) from the end of a 3/8 drill bit. 5. Install a drill bit in a 90° degree angle drill for better clearance and drill the holes on the marks, as shown in the figure. 6. Vacuum up the foam and metal chips. 7. After drilling the holes, it is important that the appropriate anti-corrosion primer be applied. Refer to GM Approved Refinish Materials Booklet (GM4901M-D-99) for additional information. 8. Repeat for the other side. 9. Reinstall the seat belt retractors. 10. Reinstall both quarter trim panels. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time C9047 Install Drain Path 1.0 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-110-001 > Mar > 10 > Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-08-110-001 > Mar > 10 > Interior - Proper Use of Floor Mats > Page 10255 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 10260 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 10261 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet Carpet: All Technical Service Bulletins Interior - Rear Footwell Wet File In Section: 08 - Body and Accessories Bulletin No.: 99-08-65-001 Date: March, 1999 TECHNICAL Subject: Rear Footwell Wet (Insert Drain Path) Models: 1995-98 Chevrolet Cavalier Convertible Only 1995-98 Pontiac Sunfire Convertible Only Condition Some customers may comment that the rear floor is wet. Cause When the vehicle is parked nose down on a steep incline, during a hard or prolonged rain, water may accumulate in the front seat belt retractor area. This could result in flooding over the poured-in-place foam and then into the passenger compartment. Correction Add the drain path, using the following procedure: 1. Remove the RH and LH rear quarter trim panels. 2. Remove the RH and LH lower seat belt retractor bolts and set the retractor aside. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-65-001 > Mar > 99 > Interior - Rear Footwell Wet > Page 10266 3. See the figure for approximate locations for the 10 mm (3/8 in.) drain holes in the foam. Hole location is critical. 4. Install a drill stop placed approximately 32 mm (1-1/4 in.) from the end of a 3/8 drill bit. 5. Install a drill bit in a 90° degree angle drill for better clearance and drill the holes on the marks, as shown in the figure. 6. Vacuum up the foam and metal chips. 7. After drilling the holes, it is important that the appropriate anti-corrosion primer be applied. Refer to GM Approved Refinish Materials Booklet (GM4901M-D-99) for additional information. 8. Repeat for the other side. 9. Reinstall the seat belt retractors. 10. Reinstall both quarter trim panels. Warranty Information For vehicles repaired under warranty, use: Labor Labor Operation Description Time C9047 Install Drain Path 1.0 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > 73-83-09 > May > 97 > Cooling - Low Coolant Light On During Sustained Driving Radiator Surge Tank: All Technical Service Bulletins Cooling - Low Coolant Light On During Sustained Driving File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-83-09 Date: May, 1997 Subject: Low Engine Coolant Light On During Sustained Driving at Moderate to High Engine RPM (Replace Cooling System Surge Tank) Models: 1997 Chevrolet Cavalier 1997 Pontiac Sunfire Built from SOP through December 31, 1996 Condition Some owners may comment that the low engine coolant light will illuminate during sustained driving at moderate to high engine RPM. Cause The design of the baffles in the cooling system surge tank coupled with the engine coolant air bleed pipe allow high coolant flow. This may allow the coolant sensor cavity in the surge tank to have an inadequate supply of coolant during sustained driving at moderate to high engine RPM. This may cause the low coolant light to illuminate even if the system is properly filled. Correction Verify that the system is properly filled and free of leaks. If the condition is still present, replace the cooling system surge tank with the revised design (see below for P/N's). Refer to the 1997 Service Manual. Parts Information Old P/N New P/N Description 22600776 22605500 For Chevrolet Cavalier and Pontiac Sunfire Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time J3250 Tank, Radiator Use published Coolant Surge - labor operation R&R; or Replace time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations LH I/P And Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 10280 LH Center Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement Console: Service and Repair Console Replacement Description Remove or Disconnect 1. Open console compartment. 2. Console trim plate or hoot. 3. Screw cover. 4. Four screws. 5. Console. Install or Connect 1. Console. 2. Screws. 3. Screw cover. 4. Console trim plate or boot. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 10283 Console: Service and Repair Console Trim Plate Description Remove or Disconnect 1. Gently pry upward to disengage retainers. 2. Gear shift handle. Install or Connect 1. Gear shift handle. 2. Align retainers and press in place. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 10284 Console: Service and Repair Shifter Handle Description Remove or Disconnect 1. Retainer from shift handle. 2. ETS wire connector and pull wire through shift boot. 3. Shift handle from shift control lever. Install or Connect 1. ETC wire through shift lever boot and connect electrical connector. 2. Shift handle to shift control lever. 3. Shift handle retainer. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 10285 Console: Service and Repair Sound Insulators Remove or Disconnect 1. Screws to I/P. 2. Sound insulator. Install or Connect 1. Sound insulator to I/P. 2. Screws to I/P. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel to the straight ahead position. ^ Remove the key from the ignition switch. 1. The AIR BAG fuse from the I/P fuse block. 2. The I/P sound insulator - (LH). 3. The Connector Position Assurance (CPA) and the driver yellow 2-way connector located at the base of the steering column. 4. The Connector Position Assurance (CPA) and the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10291 IMPORTANT With the AIR BAG fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is normal operation and does not indicate a SIR system malfunction. Enabling the SIR System INSTALL OR CONNECT ^ Remove the key from the ignition switch. 1. The passenger yellow 2-way connector and the CPA located near the base of the steering column. 2. The driver yellow 2-way connector and the CPA located at the base of the steering column. 3. The I/P sound insulator - (LH). 4. The AIR BAG fuse to the I/P fuse block. Staying well away from both air bags, turn the ignition switch to the RUN position. Verify that the AIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10292 BAG warning lamp flashes seven times and then stays off. If the AIR BAG warning lamp does not operate as described, perform the SIR DIAGNOSTIC SYSTEM CHECK. See: Restraint Systems/Air Bag Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10293 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn off the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR System prevents deploying of the air bags from the reserve energy supply power. Refer to Disabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Remove or Disconnect 1. Gently squeeze lamp tabs together. 2. Electrical connector. Install or Connect 1. Electrical connector. 2. Align retainers and press into place. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10302 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10303 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10304 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Module Mounting And Wiring REMOVE OR DISCONNECT 1. Negative battery cable. 2. Open rear compartment. 3. Left inner trim panel. 4. One electrical connector. 5. Remove push pins. 6. Module. INSTALL OR CONNECT 1. Module to rear compartment brace. 2. Push pins to brace. 3. Electrical connector. 4. Rear compartment trim. 5. Close rear compartment. 6. Negative battery cable. 7. Program to match transmitter(s). Refer to "Remote Keyless Entry Module Programming". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation Module Mounting And Wiring The Remote Keyless Entry Module (receiver) is located in the luggage compartment on the left inner wheel house panel. The following information is on the module: ^ GM Part Number ^ Latest Change Level ^ Julian Date Code (4 digits) ^ Manufacturing Location Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair Transmitter Battery Replacement REMOVE OR DISCONNECT 1. Pry cover in groove with dime or small screwdriver. 2. Cover (leave seal in place). 3. One battery. INSTALL OR CONNECT 1. One battery (positive side down) CR2032 (3 volt) or equivalent. 2. Cover (put seal back into position if it came out of position in Step 2 above). 3. Snap cover into place. 4. Resynchronize the transmitter. Refer to Resynchronization. See: Service and Repair/Transmitter Synchronization 5. Check for proper operation. Normal battery life is approximately two years. The batteries should be replaced when the range of the RKE transmitter begins to decrease significantly to less than approximately seven meters (23 feet). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 10320 Door Lock Relay And Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations LH Front Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10324 Rear Window And Door Lock Switches Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > Customer Interest for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever Mirror Adjustment Handle: Customer Interest Manual Door Mirror (L/H) - Does Not Adjust With Lever File In Section: 08 - Body and Accessories Bulletin No.: 99-08-64-015 Date: September, 1999 TECHNICAL Subject: Left Hand Manual Mirror Does Not Adjust When Adjustment Lever is Moved (Adjust Lever to Align with Lever Slide) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire with Manual Mirrors This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 73-15-02 (Section 10 - Body). Condition Some owners may comment that the left hand manual mirror does not adjust when the adjustment lever is moved. Cause The adjustment lever may have become disengaged from the lever slide. Correction Caution: To avoid personal injury, do not place fingers in mirror hinge area. 1. Roll down the left door window. 2. Fold the mirror toward the front of the vehicle. Hold the mirror in position with your left hand. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > Customer Interest for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever > Page 10338 3. With your right hand, move the adjustment lever handle (inside the vehicle) to align the T end of the lever with the lever slide. 4. Fold the mirror back to the original position to engage the T end of the lever with the lever slide. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time R3261 Mirror, Outside Rear View - Use published labor Replace (Manual Left) operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever Mirror Adjustment Handle: All Technical Service Bulletins Manual Door Mirror (L/H) - Does Not Adjust With Lever File In Section: 08 - Body and Accessories Bulletin No.: 99-08-64-015 Date: September, 1999 TECHNICAL Subject: Left Hand Manual Mirror Does Not Adjust When Adjustment Lever is Moved (Adjust Lever to Align with Lever Slide) Models: 1995-2000 Chevrolet Cavalier 1995-2000 Pontiac Sunfire with Manual Mirrors This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 73-15-02 (Section 10 - Body). Condition Some owners may comment that the left hand manual mirror does not adjust when the adjustment lever is moved. Cause The adjustment lever may have become disengaged from the lever slide. Correction Caution: To avoid personal injury, do not place fingers in mirror hinge area. 1. Roll down the left door window. 2. Fold the mirror toward the front of the vehicle. Hold the mirror in position with your left hand. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Mirror Adjustment Handle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mirror Adjustment Handle: > 99-08-64-015 > Sep > 99 > Manual Door Mirror (L/H) - Does Not Adjust With Lever > Page 10344 3. With your right hand, move the adjustment lever handle (inside the vehicle) to align the T end of the lever with the lever slide. 4. Fold the mirror back to the original position to engage the T end of the lever with the lever slide. Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time R3261 Mirror, Outside Rear View - Use published labor Replace (Manual Left) operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations LH Front Door Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10348 Outside Mirror Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10358 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Paint: Customer Interest Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 10363 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10369 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler Paint: All Technical Service Bulletins Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 33-17-01A > Dec > 97 > Exhaust System - Paint Peeling from Painted Muffler > Page 10378 Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 72-05-11 > Dec > 97 > Warranty - Rail Dust Removal & Chemical Spotting Labor Paint: All Technical Service Bulletins Warranty - Rail Dust Removal & Chemical Spotting Labor File In Section: Warranty Administration Bulletin No.: 72-05-11 Date: December, 1997 WARRANTY ADMINISTRATION Subject: Clarification of Rail Dust Removal (A5575-A5580) and Chemical Spotting (A5541-A5544) Labor Operations Models: All Past and Future Passenger Cars and Light Duty Trucks The purpose of this Warranty Administration Bulletin is to clarify the usage, limits and guidelines for the proper use of the above subject labor operations. The above subject labor operations were introduced to correct paint imperfections caused by fallout that occurred either during shipment to the dealer or within the first 12 months or 12,000 miles (20,000 kms) of vehicle ownership. GM vehicle owners are informed that although no defect in the factory applied paint causes this, GM will repair, at no charge to the owner, the surfaces of new vehicles damaged by fallout condition within 12 months or 12,000 miles (20,000 kms) whichever occurs first. Effective with repair orders dated on or after December 1, 1997, labor operations A5575-A5580 Rail Dust Removal and A5541 through A5544 Chemical Spotting will be limited to within the first 12 months or 12,000 miles of the Base Vehicle Warranty (20,000 kms) whichever occurs first. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 63-17-07B > Jun > 97 > Paint - Basecoat/Clearcoat Paint Systems Specifications Paint: All Technical Service Bulletins Paint - Basecoat/Clearcoat Paint Systems Specifications File In Section: 10 - Body Bulletin No.: 63-17-07B Date: June, 1997 INFORMATION Subject: New Aftermarket Paint Specification (GM4901M) for Basecoat/Clearcoat Paint Systems (Rigid Exterior Surfaces) Models: 1993-97 Passenger Cars and Trucks This bulletin is being revised to provide additional information on approved paint systems (Attachment 1 added). Please discard Corporate Bulletin Number 63-17-07A (Section 10 - Body). A vehicle's appearance is important to any customer's perception of that vehicle's quality and value. Furthermore, when an exterior finish repair is made, the customer expects that repair to match the showroom finish. Based upon rigorous and exhaustive testing, General Motors has established an aftermarket refinish paint specification, known as GM4901M, which is listed in the GM Engineering Specifications Manual. Use this specification when selecting a paint system for General Motors vehicle warranty paint repairs. All major paint suppliers are involved and support this program. The booklet enclosed with Corporate Bulletin # 63-17-07, "GM Approved Refinish Materials", P/N GM4901 M-D, identifies the paint systems you may use. All approved products (including VOC-compliant) are listed in the "system" approach recommended by the individual manufacturer. This booklet will be updated periodically to ensure you are provided with the latest information on paint systems. GM and Paint Supplier training services encompass this new specification and can address any questions. All materials listed in the booklet fall under the current materials allowance. However, this may change as costs increase. With this program, it is our goal to ensure quality repairs. After all, skilled technicians using the right materials offer the only path to true customer enthusiasm. By adhering to the GM4901M Specification for Aftermarket Paint Repair Materials, you will ensure our customers only receive the best while maximizing your quality throughout on exterior finish repairs. When a meeting or training session is held in your area, be sure your team is represented. We look forward to your support for this program. Additional Information In the development of this paint specification, major paint suppliers were invited to submit materials for approval. The requirements of the program are included in the approved materials booklet referenced above, dated December, 1996. Important: As of 7-1-97, the BASF products listed on Attachment 1 are now approved for use. The approved suppliers are: ^ Akzo Nobel (Sikkens) ^ American Standox ^ BASF ^ DuPont ^ ICI Autocolor ^ Martin Senour ^ PPG ^ Sherwin Williams Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 63-17-07B > Jun > 97 > Paint - Basecoat/Clearcoat Paint Systems Specifications > Page 10387 ^ Spies Hecker Your Zone wholesale personnel, Training Centers, STG Field Service Engineers, and the approved suppliers have additional training materials that may answer your further questions. Use of these GM approved materials ensures the highest quality for maintaining customer satisfaction. The dealer or retailer must ensure that all refinish materials, including sublets, meet GM Specification GM4901-M. Use of materials (and associated application methods) that do not meet this GM standard may result in a review of claim(s) leading to chargeback(s), as specified in the Policies and Procedures manual, Article 1.4.17. The standards will be updated periodically and other suppliers may be added when new standards are released by the fall of 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 63-17-07B > Jun > 97 > Paint - Basecoat/Clearcoat Paint Systems Specifications > Page 10388 ATTACHMENT 1 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 72-05-11 > Dec > 97 > Warranty - Rail Dust Removal & Chemical Spotting Labor Paint: All Technical Service Bulletins Warranty - Rail Dust Removal & Chemical Spotting Labor File In Section: Warranty Administration Bulletin No.: 72-05-11 Date: December, 1997 WARRANTY ADMINISTRATION Subject: Clarification of Rail Dust Removal (A5575-A5580) and Chemical Spotting (A5541-A5544) Labor Operations Models: All Past and Future Passenger Cars and Light Duty Trucks The purpose of this Warranty Administration Bulletin is to clarify the usage, limits and guidelines for the proper use of the above subject labor operations. The above subject labor operations were introduced to correct paint imperfections caused by fallout that occurred either during shipment to the dealer or within the first 12 months or 12,000 miles (20,000 kms) of vehicle ownership. GM vehicle owners are informed that although no defect in the factory applied paint causes this, GM will repair, at no charge to the owner, the surfaces of new vehicles damaged by fallout condition within 12 months or 12,000 miles (20,000 kms) whichever occurs first. Effective with repair orders dated on or after December 1, 1997, labor operations A5575-A5580 Rail Dust Removal and A5541 through A5544 Chemical Spotting will be limited to within the first 12 months or 12,000 miles of the Base Vehicle Warranty (20,000 kms) whichever occurs first. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 63-17-07B > Jun > 97 > Paint - Basecoat/Clearcoat Paint Systems Specifications Paint: All Technical Service Bulletins Paint - Basecoat/Clearcoat Paint Systems Specifications File In Section: 10 - Body Bulletin No.: 63-17-07B Date: June, 1997 INFORMATION Subject: New Aftermarket Paint Specification (GM4901M) for Basecoat/Clearcoat Paint Systems (Rigid Exterior Surfaces) Models: 1993-97 Passenger Cars and Trucks This bulletin is being revised to provide additional information on approved paint systems (Attachment 1 added). Please discard Corporate Bulletin Number 63-17-07A (Section 10 - Body). A vehicle's appearance is important to any customer's perception of that vehicle's quality and value. Furthermore, when an exterior finish repair is made, the customer expects that repair to match the showroom finish. Based upon rigorous and exhaustive testing, General Motors has established an aftermarket refinish paint specification, known as GM4901M, which is listed in the GM Engineering Specifications Manual. Use this specification when selecting a paint system for General Motors vehicle warranty paint repairs. All major paint suppliers are involved and support this program. The booklet enclosed with Corporate Bulletin # 63-17-07, "GM Approved Refinish Materials", P/N GM4901 M-D, identifies the paint systems you may use. All approved products (including VOC-compliant) are listed in the "system" approach recommended by the individual manufacturer. This booklet will be updated periodically to ensure you are provided with the latest information on paint systems. GM and Paint Supplier training services encompass this new specification and can address any questions. All materials listed in the booklet fall under the current materials allowance. However, this may change as costs increase. With this program, it is our goal to ensure quality repairs. After all, skilled technicians using the right materials offer the only path to true customer enthusiasm. By adhering to the GM4901M Specification for Aftermarket Paint Repair Materials, you will ensure our customers only receive the best while maximizing your quality throughout on exterior finish repairs. When a meeting or training session is held in your area, be sure your team is represented. We look forward to your support for this program. Additional Information In the development of this paint specification, major paint suppliers were invited to submit materials for approval. The requirements of the program are included in the approved materials booklet referenced above, dated December, 1996. Important: As of 7-1-97, the BASF products listed on Attachment 1 are now approved for use. The approved suppliers are: ^ Akzo Nobel (Sikkens) ^ American Standox ^ BASF ^ DuPont ^ ICI Autocolor ^ Martin Senour ^ PPG ^ Sherwin Williams Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 63-17-07B > Jun > 97 > Paint - Basecoat/Clearcoat Paint Systems Specifications > Page 10402 ^ Spies Hecker Your Zone wholesale personnel, Training Centers, STG Field Service Engineers, and the approved suppliers have additional training materials that may answer your further questions. Use of these GM approved materials ensures the highest quality for maintaining customer satisfaction. The dealer or retailer must ensure that all refinish materials, including sublets, meet GM Specification GM4901-M. Use of materials (and associated application methods) that do not meet this GM standard may result in a review of claim(s) leading to chargeback(s), as specified in the Policies and Procedures manual, Article 1.4.17. The standards will be updated periodically and other suppliers may be added when new standards are released by the fall of 1997. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 63-17-07B > Jun > 97 > Paint - Basecoat/Clearcoat Paint Systems Specifications > Page 10403 ATTACHMENT 1 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10404 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10405 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 33-17-01A Date: 971201 Exhaust System - Paint Peeling from Painted Muffler Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10406 File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Labor Material Operation Labor Time Allowance Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10407 A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10408 Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10409 Disclaimer Technical Service Bulletin # 33-17-01A Date: 971201 Exhaust System - Paint Peeling from Painted Muffler File In Section: 10 - Body Bulletin No.: 33-17-01A Date: December, 1997 Subject: Paint Peeling from Muffler (New Repair Paint Available) Models: 1993-98 Passenger Cars with Painted Mufflers This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 33-17-01 (Section 10 - Body). Condition Some owners may experience paint peeling from the muffler. Correction Clean and repaint the affected area using the following procedure and product. Important: DO NOT REPLACE COMPONENTS TO REPAIR THIS CONDITION. The exhaust system must be cold to begin this procedure. Material Required: * Wabash Products # KB-318-HHHS, available in pints or quarts as ready to spray material (no mixing required). Call Wabash Products, 1-800-326-7269 or 812-232-6097 for pricing and shipping information. Procedure On a cold exhaust system: 1. Raise vehicle on hoist. 2. While supporting exhaust with a transmission jack, remove the rear exhaust system hangers and lower the exhaust. 3. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 4. Wire brush the affected area to remove flaking paint and blow off with air. 5. Sand the affected area with # 80 to 150 grit sandpaper to remove rust, dirt or other contaminants. 6. Clean the affected area with a wax and grease remover, lacquer thinner or other suitable solvent. 7. Tape off the rear lower body panels and exhaust pipes forward of mufflers to protect from overspray. 8. Apply paint to affected area in several (6 to 8) thin coats (to prevent sags and runs) obtaining approximately 1 mil paint coverage. 9. Raise exhaust system with jack, reinstall exhaust hangers, lower vehicle and remove from hoist. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10410 ^ Allow 30 minutes drying time. 10. In a well ventilated area, start engine and allow to idle for up to 30 minutes until paint is cured and dry. Important: Some "smoking" will occur while curing the paint with the engine running. The paint can be heated and cured while driving, but be careful not to get the exhaust system wet during the first 30 minutes. Warranty Information Labor Material Operation Labor Time Allowance A6150 0.6 hr - Single Exhaust GC Add 0.2 hr - Dual Exhaust GC Important: While the above procedure and materials are correct for vehicles from 1993 to 1998, the Labor Operation and Time Allowance only pertains to vehicles in the Warranty period. * We believe this source and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 10413 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair RADIATOR SUPPORT ASSEMBLY The radiator support assembly (Figure 2-1) consists of nine major components: four upper and five lower. The center reinforcement and left and right extensions are preassembled. This helps the technician to properly align the front structure. The upper support is serviced separately for efficient installation. The lower support is held in place with six bolts. It attaches to four brackets that are welded to the lower rails. These brackets are available as part of the lower rail service assembly or they can be ordered separately. Remove or Disconnect 1. Remove all related panels and components. 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Remove sealers, sound deadeners and corrosion materials as necessary. 4. Locate, mark and drill out all factory welds. Note the number of welds for installation of the service panels. 5. Remove the damaged panels in the radiator support assembly Install or Connect 1. Prepare mating surfaces and check for proper fit of the service panels. 2. On the service panels, drill 8mm (5/16") plug weld holes as necessary in the locations noted from the original assembly. 3. Position the service panels, check fit using body dimensions, and plug weld accordingly with frequent measurements to ensure proper fit. 4. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations. Reinstall all related panels and components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations LH Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations > Page 10421 Door Lock Relay And Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Module Mounting And Wiring REMOVE OR DISCONNECT 1. Negative battery cable. 2. Open rear compartment. 3. Left inner trim panel. 4. One electrical connector. 5. Remove push pins. 6. Module. INSTALL OR CONNECT 1. Module to rear compartment brace. 2. Push pins to brace. 3. Electrical connector. 4. Rear compartment trim. 5. Close rear compartment. 6. Negative battery cable. 7. Program to match transmitter(s). Refer to "Remote Keyless Entry Module Programming". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 10428 Door Lock Relay And Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair SUNROOF MODULE Remove or Disconnect 1. Sunroof in the fully closed position. 2. Sunroof opening trim lace. 3. Sunroof control switch. 4. Headlining trim finish panel. 5. Drain hose connections from the sunroof housing. 6. Sunroof module bolts. 7. Sunroof module. Install or Connect 1. Sunroof module. 2. Sunroof module bolts. Tighten ^ Bolt to 11 Nm (97 lb. in.) 3. Drain hose connections from the sunroof housing. 4. Headlining trim finish panel. 5. Sunroof control switch. 6. Sunroof opening trim lace. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage Convertible Top Canvas: Technical Service Bulletins Convertible - Top Cover Shows Wear or Permanent Damage File In Section: 10 - Body Bulletin No.: 73-10-60B Date: August, 1998 Subject: Convertible Top Cover Shows Wear or Permanent Damage in Various Areas (Perform Repair Procedure(s)) Models: 1995-97 Chevrolet Cavalier (Convertible) 1995-97 Pontiac Sunfire (Convertible) This bulletin is being revised to add labor time information. Please discard Corporate Bulletin Number 73-10-60A (Section 10-Body) Condition Some owners may comment on the convertible top cover showing wear or permanent damage at one or more of the following locations: near the top of the quarter windows, midway down on the sail panels, near the ends of the back belt molding or above the quarter panel belt outer molding. Cause Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10438 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10439 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10440 Condition may be due to one or more of the following. Refer to Figures 1 - 6. a. Sharp edge at top of the rear rails, b. Misalignment of No. 4 bow slats, c. Protruding back belt molding attaching studs, d. Protruding quarter belt tackstrip rivets, e. Missing or damaged balance link covers, f. Sharp ends at the No. 4 bow. Correction Remove convertible top cover. Refer to Topcover Assembly in Section 10-9 of the 1995/96 J-Platform Service Manual Update. a. If condition is due to sharp edge at top of the rear rails: 1. Dress the crown edge to a smooth, approximately 3.18 mm (0.125 in.) radius using a small fine-tooth file. Refer to Figure 7. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10441 2. Touch-up paint as required. b. If condition is due to misalignment of No. 4 bow slats: 1. Open the convertible top to the 3/4 open position. 2. With an assistant holding the No. 4 bow up until it stops, measure and mark 177.8 mm (7.0 in.) up from the top of the No. 4 bow slat attaching bolt at both sides of the vehicle. Measure the distance between the No. 4 bow slats and the rear rails; the distances left to right should be equal within 1.6 mm (0.063 in.) side to side. Refer to Figure 8. 3. Close the convertible top halfway. 4. Standing outside the vehicle at the side which has the lesser of the two distance dimensions, push on the No. 4 bow and bend the slats until the distances are within specification. Continually check the distances while bending the slats. Refer to Figure 9. c. If condition is due to protruding back belt molding attaching studs: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10442 1. Grind the studs at each side flush with the nuts. Refer to Figures 10 - 11. 2. Clean the area around the nuts with a clean cloth dampened with isopropyl (rubbing) alcohol. 3. Install loop fastener vertically over the nuts. d. If condition is due to protruding quarter belt tackstrip rivets: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10443 1. Inspect the first and second rivet at both sides of the vehicle; rivet length of more than 3.18 mm (0.125 in.) from vehicle body will require grinding. The first rivet at each side may be covered with a sealing patch that will need to be removed. Refer to Figures 12 - 13. 2. Grind the rivets until they are within the limit. Be careful not to grind too much of the rivet. 3. Clean the area around the rivets which were ground down with a clean cloth dampened with isopropyl (rubbing alcohol). 4. Install loop fastener vertically over all the rivets. e. If condition is due to missing or damaged balance link covers: 1. Open the convertible top to the 1/2 open position. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10444 2. Apply weatherstrip adhesive to the inside surface and along the split of the balance link cover. Refer to Figure 14. 3. Install the balance link cover, P/N 12368122. Make sure that the top of the balance link cover is at the second bend of the balance link. Refer to Figure 15. 4. Repeat for the other side. f. If condition is due to sharp ends at the No. 4 bow: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Canvas > Component Information > Technical Service Bulletins > Convertible - Top Cover Shows Wear or Permanent Damage > Page 10445 1. Dress the ends to a smooth radius using a small fine-tooth file. Refer to Figure 16. Install convertible top cover. Refer to Topcover Assembly in Section 10-9 of the 1995/96 J-Platform Service Manual Update. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header Convertible Top Frame: Customer Interest Convertible Top - Water Leak at Front Header File In Section: 08 - Body and Accessories Bulletin No.: 99-08-57-019 Date: May, 1999 TECHNICAL Subject: Water Leak at Front Header (Measure/Remove Material, install Shims) Models: 1995-99 Chevrolet Cavalier (Convertible Only) 1995-99 Pontiac Sunfire (Convertible Only) Condition Some customers may comment that there is a water leak at the outboard corners of the convertible top interior. Correction ^ Strikers are adjusted rearward to allow the front leading edge of bow to contact the seal In plain view (distance from header to convertible top should be 10-13 mm (25/54 - 1/2). The front edge of the convertible top (or # 1 bow) must contact the seal. No visible gaps allowed (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10454 ^ Check under the striker for shim. One shim is required under # 1 bow strikers (see Figure 2). Add shim if necessary. Important: The new top cover single seam design built after June, 1998 requires one shim per striker. Two piece top cover single seam (see Figure 2). ^ Tops built prior to June, 1998 with the header welt, P/N 12365667 were built with two shims per striker. Three piece top cover (see Figure 3). Important: This procedure requires the use of an upholstery type or automotive trim stapler by a technician knowledgeable in replacement of the convertible top cover material. If you intend to sublet vehicles requiring this repair to an independent automotive trim shop, please supply them with this Service Bulletin. ^ The top cover installation over the front leading edge of the # 1 bow, must be free of wrinkles for good seal to the header. See highlighted area in Figure 2. ^ The outboard edge binding must be trimmed 12.7-19.05 mm (1/2 - 1/4 in) long and stapled at the edges with stainless steel staples (see Figure 2). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10455 Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header Convertible Top Frame: All Technical Service Bulletins Convertible Top - Water Leak at Front Header File In Section: 08 - Body and Accessories Bulletin No.: 99-08-57-019 Date: May, 1999 TECHNICAL Subject: Water Leak at Front Header (Measure/Remove Material, install Shims) Models: 1995-99 Chevrolet Cavalier (Convertible Only) 1995-99 Pontiac Sunfire (Convertible Only) Condition Some customers may comment that there is a water leak at the outboard corners of the convertible top interior. Correction ^ Strikers are adjusted rearward to allow the front leading edge of bow to contact the seal In plain view (distance from header to convertible top should be 10-13 mm (25/54 - 1/2). The front edge of the convertible top (or # 1 bow) must contact the seal. No visible gaps allowed (see Figure 1). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10461 ^ Check under the striker for shim. One shim is required under # 1 bow strikers (see Figure 2). Add shim if necessary. Important: The new top cover single seam design built after June, 1998 requires one shim per striker. Two piece top cover single seam (see Figure 2). ^ Tops built prior to June, 1998 with the header welt, P/N 12365667 were built with two shims per striker. Three piece top cover (see Figure 3). Important: This procedure requires the use of an upholstery type or automotive trim stapler by a technician knowledgeable in replacement of the convertible top cover material. If you intend to sublet vehicles requiring this repair to an independent automotive trim shop, please supply them with this Service Bulletin. ^ The top cover installation over the front leading edge of the # 1 bow, must be free of wrinkles for good seal to the header. See highlighted area in Figure 2. ^ The outboard edge binding must be trimmed 12.7-19.05 mm (1/2 - 1/4 in) long and stapled at the edges with stainless steel staples (see Figure 2). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Frame: > 99-08-57-019 > May > 99 > Convertible Top - Water Leak at Front Header > Page 10462 Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Motor > Component Information > Locations LH Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Relay > Component Information > Locations LH Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Relay > Component Information > Locations > Page 10469 Door Lock Relay And Folding Top Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Switch > Component Information > Locations Convertible Top Switch: Locations Top Of Windshield Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Convertible Top Weatherstrip: > 83-10-94 > Mar > 98 > Convertible Top - Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: Customer Interest Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Convertible Top Weatherstrip: > 83-10-94 > Mar > 98 > Convertible Top - Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: All Technical Service Bulletins Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair Sunroof / Moonroof Cable: Service and Repair SUNROOF TRACK AND DRIVE CABLE Remove 1. Sunroof in the fully closed position. 2. Sunroof module. 3. Sunroof motor. 4. Sunroof cable wear plate rivet. 5. Sunroof cable wear plate. 6. Sunroof track screws. 7. Sunroof drive tube retainer with a small flat blade tool. 8. Sunroof track and drive cable. Install 1. Sunroof track and drive cable. 2. Sunroof drive tube retainer. 3. Sunroof track screws. Tighten Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair > Page 10490 ^ Screw to Fully Driven, Seated, Not Stripped. 4. Sunroof cable wear plate. 5. Sunroof cable wear plate rivet. 6. Sunroof motor. 7. Sunroof module. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair SUNROOF MOTOR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 10494 NOTICE: This sunroof system is timed from the factory so that the motor shuts off automatically when the sunroof window reaches a certain position. Extreme care must be taken when removing the motor from the sunroof module or this timing may be thrown off causing damage to the sunroof system. Anytime the motor needs to be removed from the module the sunroof window must be in the fully closed position. Remove or Disconnect 1. Sunroof in the fully closed position. 2. Windshield side upper garnish moldings. 3. Sunshade screws. 4. Sunshades. 5. Sunroof control switch. 6. Sunroof opening trim lace. 7. Lower headlining trim finish panel as required. 8. Wire harness connectors from motor. 9. If sunroof window is not in the full close position, there is a Allen head screw on the drive gear of the motor that is accessible with the motor. in place. If there is a red retainer surrounding the screw remove it using a small flat blade screwdriver. Using the appropriate size Allen wrench, turn the screw until the glass is fully closed. It may require a significant amount of force at first to begin to move the motor with the wrench. After the glass is fully closed back the screw off approximately 15 degrees. 10. Sunroof motor bracket bolts. 11. Sunroof motor. Adjust ^ Before installing a new motor or re-installing the old motor, check to be sure that the motor is timed to the closed position. Install or Connect 1. Sunroof motor. 2. Sunroof motor bracket bolts. Tighten ^ Bolt to Fully Driven, Seated, Not Stripped. 3. Wire harness connectors to the sunroof motor. 4. Sunroof opening trim lace. 5. Sunroof control switch. 6. Sunshade. 7. Sunshade screw. Tighten ^ Screws to Fully Driven, Seated, Not Stripped. 8. Windshield side upper garnish moldings. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 10498 Sunroof / Moonroof Switch: Service and Repair SUNROOF CONTROL SWITCH Remove 1. Using a small flat blade tool, disengage switch from headlining module 2. Connector from the switch, switch from vehicle. Install 1. Connector to the switch 2. Firmly push the switch into the headlining module to secure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair SUNROOF MODULE Remove or Disconnect 1. Sunroof in the fully closed position. 2. Sunroof opening trim lace. 3. Sunroof control switch. 4. Headlining trim finish panel. 5. Drain hose connections from the sunroof housing. 6. Sunroof module bolts. 7. Sunroof module. Install or Connect 1. Sunroof module. 2. Sunroof module bolts. Tighten ^ Bolt to 11 Nm (97 lb. in.) 3. Drain hose connections from the sunroof housing. 4. Headlining trim finish panel. 5. Sunroof control switch. 6. Sunroof opening trim lace. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Seats - Head Rest Removal/Install Procedure Revised Head Rest: Technical Service Bulletins Seats - Head Rest Removal/Install Procedure Revised File In Section: 10 - Body Bulletin No.: 73-16-02 Date: February, 1997 SERVICE MANUAL UPDATE Subject: Section 10 - Revised Remove/Install Procedure for Head Rest Models: 1997 Chevrolet Cavalier (Coupe) 1997 Pontiac Sunfire (Coupe) This bulletin is being issued to revise the remove/install procedure for On-Vehicle Service "Head Rest" found on page 10-10-2 of the Service Manual. The included artwork (Figure 1) replaces Figure 2 on page 10-10-4 of the Service Manual. Remove or Disconnect Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Technical Service Bulletins > Seats - Head Rest Removal/Install Procedure Revised > Page 10507 1. Raise head rest off of seatback. 2. Working from back side of seatback, locate head rest guide tube by moving seatback cover trim to right side of seat near head rest post, refer to Figure 1. 3. Apply upward tension to head rest using one hand. 4. Using tool J 42214-A, or equivalent, slide tip of tool down along right rear side of head rest guide tube and release retaining clip by pushing tool towards right side of seat, refer to Figure 1. 5. Continue to apply upward tension to head rest to prevent first clip from re-engaging. Repeat procedure on other head rest guide tube to remove head rest assembly from seatback. Install or Connect 1. Head rest by inserting posts into guide tubes and push head rest to the lowest position. 2. Pull up on head rest to check that lock springs are engaged and prevent head rest from being removed. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Back: Customer Interest Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10520 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10521 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 731601 > Feb > 97 > Seats - Rattle/Squeak From Passenger Side Rear Seatback Seat Back: Customer Interest Seats - Rattle/Squeak From Passenger Side Rear Seatback File In Section: 10 - Body Bulletin No.: 73-16-01 Date: February, 1997 Subject: Rattle/Squeak from Passenger (Right) Side of Rear Folding Seatback Area (Reposition Right Hand Frame Arm) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire Condition Some owners may comment on a rattle/squeak coming from the passenger (right) side of the rear folding seatback area when the rear seat is unoccupied. Cause The condition may be due to excessive clearance between the rear seatback frame and body pivot brackets. Correction To correct this condition, remove rear seatback and reposition the right hand frame arm as follows: 1. Remove rear seatback. Refer to Rear Seatback in the appropriate Service Manual. 2. Reposition right hand frame arm by moving outboard approximately 8 mm (0.31 in.). Check the new minimum width dimension of 1086 mm Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 731601 > Feb > 97 > Seats - Rattle/Squeak From Passenger Side Rear Seatback > Page 10526 (42.75 in.) from the left hand frame arm to the right hand frame arm. Refer to Figure 1. 3. Install rear seatback. Refer to Rear Seatback in the appropriate Service Manual. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C7188 0.2 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Back: All Technical Service Bulletins Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10532 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10533 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 83-10-95 > Feb > 98 > Seatback Striker, Rear - Add Remove/Install Procedure Seat Back: All Technical Service Bulletins Seatback Striker, Rear - Add Remove/Install Procedure File In Section: 10 - Body Bulletin No.: 83-10-95 Date: February, 1998 SERVICE MANUAL UPDATE Subject: Section 10-13 - Add Remove/Install Procedure for Rear Seatback Striker Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to add a new service procedure to Section 10-13 of the Service Manual. All 1995-98 Chevrolet Cavalier and Pontiac Sunfire convertibles each have four shims (two per attached bolt) located behind the rear seat striker. The striker is a carryover from the coupe; however, shimming the striker is convertible only. Please add the following procedure to Section 10-13 of the Service Manual. Rear Seatback Striker (Convertible Only) Figure 1 Remove or Disconnect 1. Rear seatback. 2. Boot center section. 3. Rear shelf carpet from the bottom of the closeout panel, as necessary. 4. Bolts, seat striker and the two shims. Install or Connect 1. Two shims, seat striker and the bolts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 83-10-95 > Feb > 98 > Seatback Striker, Rear - Add Remove/Install Procedure > Page 10538 Tighten Tighten rear seat striker bolts to 10 N.m (88.5 lb in.). 2. Rear shelf carpet to the bottom of the closeout panel. 3. Boot center section. 4. Rear seatback. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 731601 > Feb > 97 > Seats - Rattle/Squeak From Passenger Side Rear Seatback Seat Back: All Technical Service Bulletins Seats - Rattle/Squeak From Passenger Side Rear Seatback File In Section: 10 - Body Bulletin No.: 73-16-01 Date: February, 1997 Subject: Rattle/Squeak from Passenger (Right) Side of Rear Folding Seatback Area (Reposition Right Hand Frame Arm) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire Condition Some owners may comment on a rattle/squeak coming from the passenger (right) side of the rear folding seatback area when the rear seat is unoccupied. Cause The condition may be due to excessive clearance between the rear seatback frame and body pivot brackets. Correction To correct this condition, remove rear seatback and reposition the right hand frame arm as follows: 1. Remove rear seatback. Refer to Rear Seatback in the appropriate Service Manual. 2. Reposition right hand frame arm by moving outboard approximately 8 mm (0.31 in.). Check the new minimum width dimension of 1086 mm Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 731601 > Feb > 97 > Seats - Rattle/Squeak From Passenger Side Rear Seatback > Page 10543 (42.75 in.) from the left hand frame arm to the right hand frame arm. Refer to Figure 1. 3. Install rear seatback. Refer to Rear Seatback in the appropriate Service Manual. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C7188 0.2 hr Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 83-10-95 > Feb > 98 > Seatback Striker, Rear - Add Remove/Install Procedure Seat Back: All Technical Service Bulletins Seatback Striker, Rear - Add Remove/Install Procedure File In Section: 10 - Body Bulletin No.: 83-10-95 Date: February, 1998 SERVICE MANUAL UPDATE Subject: Section 10-13 - Add Remove/Install Procedure for Rear Seatback Striker Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to add a new service procedure to Section 10-13 of the Service Manual. All 1995-98 Chevrolet Cavalier and Pontiac Sunfire convertibles each have four shims (two per attached bolt) located behind the rear seat striker. The striker is a carryover from the coupe; however, shimming the striker is convertible only. Please add the following procedure to Section 10-13 of the Service Manual. Rear Seatback Striker (Convertible Only) Figure 1 Remove or Disconnect 1. Rear seatback. 2. Boot center section. 3. Rear shelf carpet from the bottom of the closeout panel, as necessary. 4. Bolts, seat striker and the two shims. Install or Connect 1. Two shims, seat striker and the bolts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 83-10-95 > Feb > 98 > Seatback Striker, Rear - Add Remove/Install Procedure > Page 10549 Tighten Tighten rear seat striker bolts to 10 N.m (88.5 lb in.). 2. Rear shelf carpet to the bottom of the closeout panel. 3. Boot center section. 4. Rear seatback. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10554 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10555 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10556 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10557 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10558 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Cushion: Customer Interest Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10567 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10568 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside Seat Cushion: All Technical Service Bulletins Front Bucket Seat - Material Bulge in Top Backside File In Section: 08 - Body and Accessories Bulletin No.: 99-08-50-007 Date: April, 1999 TECHNICAL Subject: Material Bulge in Top Backside of Front Bucket Seat (Add Plastic Tie Straps to Seat Frame) Models: 1995-98 Chevrolet Cavalier 1995-98 Pontiac Sunfire Condition Some customers may comment that there is a bulge (2) in the material on the top backside of either front bucket seat (1). Cause The suspension located inside the seat back may have slipped out of position on the seat back frame. Correction Reposition the suspension on the seat back frame and secure with a plastic tie strap, using the following procedure: Important: Refer to the Seats sub-section in the appropriate Service Manual for additional information on seat removal, disassembly, reassembly and installation. 1. Remove the seat from the vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10574 2. Remove the headrest. 3. Remove the recliner cover. 4. Disconnect the Easy Entry Adjuster Cable from the seat track adjuster (passenger seat only). 5. Remove the bolts attaching the recliner and the pivot to the seat cushion assembly and separate the seat back assembly from the seat cushion assembly. 6. Remove the seat back lock release lever knob (coupe and convertible only). 7. Unhook the closeout strip at the bottom of the seat back cover. 8. Unhook the seat back foam from the bottom of the seat back frame. 9. Pull the seat back frame out from the seat back foam pad and cover assembly. 10. Reposition the suspension (4) onto the front side of the seat frame (1), insuring that the slip sheeting (2) is between the frame and the suspension. Important: When installing the plastic tie straps in the next step, keep the ends of the tie straps to the inboard side of the seat back frame. 11. Secure both sides of the suspension to the seat back frame with plastic tie straps (3) as shown. Position the tie straps with the ends inboard of the seat back frame. 12. Cut off any excess length from both plastic tie straps (5). 13. Insert the seat back frame assembly inside the seat back foam pad and cover assembly and re-hook bottom of foam to the frame. 14. Re-hook the closeout strip on the bottom of the seat back cover. 15. Install the seat back lock release lever knob (coupe and convertible only). 16. Position the seat back frame assembly to the seat cushion assembly. Install the two recliner bolts and tighten to 24 N.m (16 lb ft). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-50-007 > Apr > 99 > Front Bucket Seat - Material Bulge in Top Backside > Page 10575 Important: Apply Loctite® # 242 Blue Threadlocker, or equivalent, to the threads of the one pivot bolt during installation in Step 17. 17. Install the white bushing, large washer and pivot bolt and tighten to 23 N.m (17 lb ft). 18. Reconnect the Easy Adjuster Cable to the seat track adjuster (passenger seat only). 19. Install the recliner cover. 20. Install the headrest. 21. Install the seat in the vehicle. Tighten nuts to 29 N.m (22 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: All Technical Service Bulletins A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10585 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10586 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10587 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10588 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10589 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10590 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10600 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10601 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10602 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10603 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10604 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cushion: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 10605 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Page 10606 RH I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Convertible Top Switch > Component Information > Locations Convertible Top Switch: Locations Top Of Windshield Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations LH Front Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10614 Rear Window And Door Lock Switches Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations LH Front Door Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10618 Outside Mirror Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 10622 Sunroof / Moonroof Switch: Service and Repair SUNROOF CONTROL SWITCH Remove 1. Using a small flat blade tool, disengage switch from headlining module 2. Connector from the switch, switch from vehicle. Install 1. Connector to the switch 2. Firmly push the switch into the headlining module to secure. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 83-10-94 > Mar > 98 > Convertible Top - Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: Customer Interest Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-10-94 > Mar > 98 > Convertible Top - Waterleak Between Side Rail & Cover Convertible Top Weatherstrip: All Technical Service Bulletins Convertible Top - Waterleak Between Side Rail & Cover File In Section: 10 - Body Bulletin No.: 83-10-94 Date: March, 1998 Subject: Waterleak between the Convertible Top Cover and the Front and/or Side Rail - RH/LH (Add Secondary Weatherstrip) Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) Condition Some owners may comment on water entering the vehicle from the convertible top side rails. Water may collect in side rails and be noticed when top is lowered. Cause During condition of high water pressure, the top cover may lift from side rails, allowing water intrusion. Correction Install a secondary weatherstrip to the left and right hand front and center rails, using kit P/N 12366099. Installation instructions are included with each kit. Parts Information P/N Description 12366099 Kit Secondary Weatherstrip Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time C1536/37 Use published labor operation time Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Convertible Top Weatherstrip: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Convertible Top Weatherstrip: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 10642 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Convertible Top Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Convertible Top Weatherstrip: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 10648 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10653 Brake Switch (Cruise Control): Description and Operation The cruise control release switch and stoplamp switch assemblies are used to disengage the cruise control system. A release switch and stoplamp switch assembly mounted on the brake pedal bracket disengages the system electrically when the brake pedal is depressed. This is done by activating the brake cut-out input to the cruise control module assembly. The speed of the vehicle at brake actuation will be stored in the memory of the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10654 Brake Switch (Cruise Control): Adjustments The release switch assembly and the stoplamp switch assembly cannot be adjusted until after the brake booster pushrod is assembled to the brake pedal assembly. The cruise control release switch and the stoplamp switch are adjusted together. Incorrect adjustment could cause the cruise control system to not work properly. Adjust 1. Press brake pedal assembly and insert switch assembly and stoplamp switch assembly into retainers until fully seated. 2. Slowly release brake pedal assembly back to its fully retracted position. The release switch assembly will move within retainers to their adjusted" position. Measure The following brake pedal assembly travel distances can be used to check for properly adjusted release switch assembly and stoplamp switch assembly. Release switch assembly and stoplamp switch assembly contacts must be open at 3.5 to 12.5 mm (1/8 to 1/2 inch) brake pedal assembly travel, measured at the centerline of The brake pedal assembly pad. Nominal actuation of the stoplamp switch assembly contacts is about 4.5 mm (3/16 inch) after cruise control switch assembly contacts close. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10655 Brake Switch (Cruise Control): Service and Repair Cruise Control Switches Remove or Disconnect 1. Left sound insulator. 2. Wiring harness connector(s). 3. Pull switch rearward to remove from retainer in bracket. Install or Connect 1. Retainer into bracket (from forward side). 2. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Audible "clicks" can be heard as ribbed portion of switch is pushed forward through the retainer. 3. Wiring harness connector(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10656 Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. Switch will be moved in retainer providing adjustment. b. Release brake or clutch pedal and repeat Step A to assure that switch is properly adjusted. 4. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations LH Lower I/P LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 10660 Clutch Switch: Service and Repair Cruise Control Switches Remove or Disconnect 1. Left sound insulator. 2. Wiring harness connector(s). 3. Pull switch rearward to remove from retainer in bracket. Install or Connect 1. Retainer into bracket (from forward side). 2. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Audible "clicks" can be heard as ribbed portion of switch is pushed forward through the retainer. 3. Wiring harness connector(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 10661 Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. Switch will be moved in retainer providing adjustment. b. Release brake or clutch pedal and repeat Step A to assure that switch is properly adjusted. 4. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10665 Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10666 Cruise Control Module: Service and Repair Cruise Control Module To Bracket Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10667 Cruise Control Module Mounting The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor to vary the throttle with each different cruise control mode. The module assembly is not serviceable. Remove or Disconnect 1. Negative battery cable. 2. Cruise control cable at engine bracket and Throttle Body Injection, (TBI) cam. 3. Cruise control cable from module assembly. 4. Electrical connector from module assembly. 5. Two 10 mm nuts from mounting studs (2.2L). Slide module from mounting bracket (2.4L). 6. Module assembly from right strut tower (2.2L). Module assembly from front of dash (2.4L). 7. Module assembly from mounting bracket (2.2L). Install or Connect 1. Module assembly to mounting bracket (2.2L). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10668 IMPORTANT Do not pre-tap screws to module without mounting bracket in between the module and the screw. The added length of the screw may damage the cruise control module. Tighten ^ Nuts to 12 N.m (106 lb. in.) 2. Module assembly to strut tower (2.2L). Module assembly to Front of Dash (2.4L). 3. Two nuts (2.2L). Tighten ^ Nuts to 25 N.m (18 lb. ft.) 4. Electrical connector to module. 5. Cruise control cable to module assembly. 6. Cruise control cable to engine bracket and TBI cam. 7. Adjust Cruise Control Cable. Refer to "Adjust Cruise Control Cable". 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments Cruise Control Servo Cable: Adjustments ADJUST 1. Hold TBI at closed position. 2. Adjust thumb screw. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 10672 Cruise Control Servo Cable: Service and Repair Cruise Control Cable Routing Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 10673 Accelerator Control Cable Splash Shield Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 10674 Cruise Control Cable To Throttle Bracket Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 10675 Cruise Control Cable To Module Ribbon To Cruise Control Module Remove or Disconnect 1. (LN2 ONLY) Accelerator control cable splash shield. (LD9 ONLY) Air Intake duct assembly. 2. Cruise control cable tab from TBI cam. Rotate throttle body cam to 1/4 open throttle to release tab. 3. Push locating fitting inward to release cable and pull from bracket. 4. Cable assembly from module by 1/4 turn counter-clockwise. 5. Cable from ribbon. Install or Connect 1. Cable to ribbon. 2. Cable assembly to module by 1/4 turn clockwise. 3. Cruise control cable tab to TBI cam. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 10676 4. Align cruise control cable fitting to TBI bracket and snap into place. 5. (LN2 ONLY) Accelerator control cable splash shield. (LD9 ONLY) Air intake duct assembly. 6. Adjust cruise control cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Cruise Control Switch Cruise Control Switch: Description and Operation Cruise Control Switch The Off/On/Resume/Accel Switch has three positions.This switch turns the cruise control system On and Off, and also returns cruise control operation to the last speed setting when MOMENTARILY moved towards the R/A position after braking. If the slider is held in the R/A position for more than one second, the system reverts to the Accel mode. To accelerate the vehicle, move the slider switch to the R/A position and hold it there until the vehicle reaches the desired increased speed. When the slider switch is released, the speed the vehicle accelerated to becomes the new cruise speed. In order to use the Accel mode, the cruise Off/On/Resume/Accel switch must be in the "ON" position and the vehicle must be above the low speed lockout which is approximately 40 km/h (25 mph). The slide switch may also be used to "tap-up" vehicle speed. In order to do this, the cruise must be engaged and operating. "Tapping-up" is done by quickly pressing the slide switch toward the R/A position and quickly releasing it, or "tap" the lever. Do not hold the lever in the R/A position or the system will revert to the Accel mode. "Tap-up" is a function in which cruise speed can be increased by 0.62 km/h (1 mph) increments (one tap = 1 mph increase) IMPORTANT Unless the SET button has been previously set in the current ignition cycle, R/A will not function. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Cruise Control Switch > Page 10681 Cruise Control Switch: Description and Operation Set/Coast Switch The cruise control Set/Coast Switch (located in the end of the turn signal lever) has two positions "Normal" and "Depressed." ^ The Set Position: With the button switch depressed and then released (vehicle speed must exceed the low speed lockout point, and the Off/On/Resume/Accel Switch must be in the ON position) the cruise speed will be set at the particular speed the vehicle was at when the button was released. Car cruise speed will be within 0.62 km/h (1 mph) of the actual speed when engaged and after the speed has stabilized. (NOTE: It is no longer possible to set the cruise with the RESUME button). The system will cruise until either the Off/On/Resume/Accel Switch is moved to OFF, the ignition switch is turned off, and/or the Set/Coast Button is pushed in fully and held. Pushing the brake pedal (or clutch pedal) releases the cruise but not the resume capability. ^ The Coast Position: With the button switch fully depressed, the driver can raise or lower his control speed. To increase control speed, the driver would accelerate to a new speed, fully depress the switch (controller releases previously set speed) and release the button. Upon releasing the button a new speed is set. An increased control speed can also be more easily set by the Off/On/Resume/Accel Switch as previously described. To decrease cruise speed, the button switch is held in (depressed position) disengaging the cruise system, and allowing the throttle to return to the idle position. When the vehicle has slowed to the desired lower cruise speed, releasing the switch will re-engage the system at the lower speed. ^ The "Tap-Down" Position: In order to do this the cruise must be engaged and operating. "Tapping-down" is done by quickly pressing the Set/Coast Button to the depressed position and quickly releasing it, or "tap" the button. Do not hold the button in the depressed position or the system will revert to the "coast" mode. "Tap-down" is a function in which cruise speed can be decreased by 0.62 km/h (1 mph) increments (one tap = 1 mph decrease). The system can "tap-down" until it reaches the low speed lockout 40 kin/h (25 mph), after this cruise will not operate. The accelerator may be depressed at any time to override the cruise system. Release of the accelerator will return the vehicle to the previously set cruise speed. NOTICE: To keep the vehicle under control, and to prevent possible vehicle damaged, it is not advisable to use the Cruise Control on slippery roads. It is not recommended to use the cruise control in conditions such as on winding roads or in traffic of heavy or varying volume. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Brake and Clutch Pedal Switches Cruise Control Switch: Service and Repair Brake and Clutch Pedal Switches Description Description Remove or Disconnect 1. Left sound insulator. 2. Pull switch rearward to remove from retainer in bracket 3. Wiring Harness connectors. Install or Connect 1. Wiring harness to switch. 2. Retainer into bracket (from forward side). 3. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. b. Switch will be moved in retainer providing adjustment. c. Release brake or clutch pedal and repeat Step "a" to assure that switch is properly adjusted. 4. Wiring harness connector(s). 5. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Brake and Clutch Pedal Switches > Page 10684 Cruise Control Switch: Service and Repair Engagement Switch The cruise control engagement switch is part of the turn signal lever assembly and is not serviceable by itself. The turn signal lever and cruise control switch must be replaced as an assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations LH Rear Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10689 Cruise Control Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10690 Cruise Control Module: Service and Repair Cruise Control Module To Bracket Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10691 Cruise Control Module Mounting The cruise control module assembly is mounted on the right front strut tower. The module assembly has an electronic controller and an electric stepper motor to vary the throttle with each different cruise control mode. The module assembly is not serviceable. Remove or Disconnect 1. Negative battery cable. 2. Cruise control cable at engine bracket and Throttle Body Injection, (TBI) cam. 3. Cruise control cable from module assembly. 4. Electrical connector from module assembly. 5. Two 10 mm nuts from mounting studs (2.2L). Slide module from mounting bracket (2.4L). 6. Module assembly from right strut tower (2.2L). Module assembly from front of dash (2.4L). 7. Module assembly from mounting bracket (2.2L). Install or Connect 1. Module assembly to mounting bracket (2.2L). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10692 IMPORTANT Do not pre-tap screws to module without mounting bracket in between the module and the screw. The added length of the screw may damage the cruise control module. Tighten ^ Nuts to 12 N.m (106 lb. in.) 2. Module assembly to strut tower (2.2L). Module assembly to Front of Dash (2.4L). 3. Two nuts (2.2L). Tighten ^ Nuts to 25 N.m (18 lb. ft.) 4. Electrical connector to module. 5. Cruise control cable to module assembly. 6. Cruise control cable to engine bracket and TBI cam. 7. Adjust Cruise Control Cable. Refer to "Adjust Cruise Control Cable". 8. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10697 Brake Switch (Cruise Control): Description and Operation The cruise control release switch and stoplamp switch assemblies are used to disengage the cruise control system. A release switch and stoplamp switch assembly mounted on the brake pedal bracket disengages the system electrically when the brake pedal is depressed. This is done by activating the brake cut-out input to the cruise control module assembly. The speed of the vehicle at brake actuation will be stored in the memory of the system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10698 Brake Switch (Cruise Control): Adjustments The release switch assembly and the stoplamp switch assembly cannot be adjusted until after the brake booster pushrod is assembled to the brake pedal assembly. The cruise control release switch and the stoplamp switch are adjusted together. Incorrect adjustment could cause the cruise control system to not work properly. Adjust 1. Press brake pedal assembly and insert switch assembly and stoplamp switch assembly into retainers until fully seated. 2. Slowly release brake pedal assembly back to its fully retracted position. The release switch assembly will move within retainers to their adjusted" position. Measure The following brake pedal assembly travel distances can be used to check for properly adjusted release switch assembly and stoplamp switch assembly. Release switch assembly and stoplamp switch assembly contacts must be open at 3.5 to 12.5 mm (1/8 to 1/2 inch) brake pedal assembly travel, measured at the centerline of The brake pedal assembly pad. Nominal actuation of the stoplamp switch assembly contacts is about 4.5 mm (3/16 inch) after cruise control switch assembly contacts close. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10699 Brake Switch (Cruise Control): Service and Repair Cruise Control Switches Remove or Disconnect 1. Left sound insulator. 2. Wiring harness connector(s). 3. Pull switch rearward to remove from retainer in bracket. Install or Connect 1. Retainer into bracket (from forward side). 2. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Audible "clicks" can be heard as ribbed portion of switch is pushed forward through the retainer. 3. Wiring harness connector(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10700 Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. Switch will be moved in retainer providing adjustment. b. Release brake or clutch pedal and repeat Step A to assure that switch is properly adjusted. 4. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations LH Lower I/P LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 10704 Clutch Switch: Service and Repair Cruise Control Switches Remove or Disconnect 1. Left sound insulator. 2. Wiring harness connector(s). 3. Pull switch rearward to remove from retainer in bracket. Install or Connect 1. Retainer into bracket (from forward side). 2. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Audible "clicks" can be heard as ribbed portion of switch is pushed forward through the retainer. 3. Wiring harness connector(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 10705 Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. Switch will be moved in retainer providing adjustment. b. Release brake or clutch pedal and repeat Step A to assure that switch is properly adjusted. 4. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Cruise Control Switch Cruise Control Switch: Description and Operation Cruise Control Switch The Off/On/Resume/Accel Switch has three positions.This switch turns the cruise control system On and Off, and also returns cruise control operation to the last speed setting when MOMENTARILY moved towards the R/A position after braking. If the slider is held in the R/A position for more than one second, the system reverts to the Accel mode. To accelerate the vehicle, move the slider switch to the R/A position and hold it there until the vehicle reaches the desired increased speed. When the slider switch is released, the speed the vehicle accelerated to becomes the new cruise speed. In order to use the Accel mode, the cruise Off/On/Resume/Accel switch must be in the "ON" position and the vehicle must be above the low speed lockout which is approximately 40 km/h (25 mph). The slide switch may also be used to "tap-up" vehicle speed. In order to do this, the cruise must be engaged and operating. "Tapping-up" is done by quickly pressing the slide switch toward the R/A position and quickly releasing it, or "tap" the lever. Do not hold the lever in the R/A position or the system will revert to the Accel mode. "Tap-up" is a function in which cruise speed can be increased by 0.62 km/h (1 mph) increments (one tap = 1 mph increase) IMPORTANT Unless the SET button has been previously set in the current ignition cycle, R/A will not function. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Cruise Control Switch > Page 10710 Cruise Control Switch: Description and Operation Set/Coast Switch The cruise control Set/Coast Switch (located in the end of the turn signal lever) has two positions "Normal" and "Depressed." ^ The Set Position: With the button switch depressed and then released (vehicle speed must exceed the low speed lockout point, and the Off/On/Resume/Accel Switch must be in the ON position) the cruise speed will be set at the particular speed the vehicle was at when the button was released. Car cruise speed will be within 0.62 km/h (1 mph) of the actual speed when engaged and after the speed has stabilized. (NOTE: It is no longer possible to set the cruise with the RESUME button). The system will cruise until either the Off/On/Resume/Accel Switch is moved to OFF, the ignition switch is turned off, and/or the Set/Coast Button is pushed in fully and held. Pushing the brake pedal (or clutch pedal) releases the cruise but not the resume capability. ^ The Coast Position: With the button switch fully depressed, the driver can raise or lower his control speed. To increase control speed, the driver would accelerate to a new speed, fully depress the switch (controller releases previously set speed) and release the button. Upon releasing the button a new speed is set. An increased control speed can also be more easily set by the Off/On/Resume/Accel Switch as previously described. To decrease cruise speed, the button switch is held in (depressed position) disengaging the cruise system, and allowing the throttle to return to the idle position. When the vehicle has slowed to the desired lower cruise speed, releasing the switch will re-engage the system at the lower speed. ^ The "Tap-Down" Position: In order to do this the cruise must be engaged and operating. "Tapping-down" is done by quickly pressing the Set/Coast Button to the depressed position and quickly releasing it, or "tap" the button. Do not hold the button in the depressed position or the system will revert to the "coast" mode. "Tap-down" is a function in which cruise speed can be decreased by 0.62 km/h (1 mph) increments (one tap = 1 mph decrease). The system can "tap-down" until it reaches the low speed lockout 40 kin/h (25 mph), after this cruise will not operate. The accelerator may be depressed at any time to override the cruise system. Release of the accelerator will return the vehicle to the previously set cruise speed. NOTICE: To keep the vehicle under control, and to prevent possible vehicle damaged, it is not advisable to use the Cruise Control on slippery roads. It is not recommended to use the cruise control in conditions such as on winding roads or in traffic of heavy or varying volume. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Brake and Clutch Pedal Switches Cruise Control Switch: Service and Repair Brake and Clutch Pedal Switches Description Description Remove or Disconnect 1. Left sound insulator. 2. Pull switch rearward to remove from retainer in bracket 3. Wiring Harness connectors. Install or Connect 1. Wiring harness to switch. 2. Retainer into bracket (from forward side). 3. With brake or clutch pedal depressed, insert switch into retainer until switch seats on retainer. Adjust a. Pull brake or clutch pedal fully rearward against pedal stop until audible "clicks" can not be heard. b. Switch will be moved in retainer providing adjustment. c. Release brake or clutch pedal and repeat Step "a" to assure that switch is properly adjusted. 4. Wiring harness connector(s). 5. Sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Brake and Clutch Pedal Switches > Page 10713 Cruise Control Switch: Service and Repair Engagement Switch The cruise control engagement switch is part of the turn signal lever assembly and is not serviceable by itself. The turn signal lever and cruise control switch must be replaced as an assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation LAMP ILLUMINATION When the Electronic Brake Control Module (EBCM) needs to illuminate the ABS indicator lamp, it will transmit a signal (via serial data link) to the Electronic Instrument Panel Cluster (IPC) and the IPC will illuminate the indicator lamp. The Amber ABS Indicator Lamp - will be illuminated to alert the driver of a malfunction. This indicates that the malfunction affects operation of the ABS. Normal (non-antilock) braking will remain. In order to regain ABS braking ability, the ABS must be serviced. As a bulb check procedure, the EBCM will command the ABS indicator lamp ON for 3 seconds when the EBCM receives power (ignition in RUN or START positions). With the ignition in the OFF/UNLOCK position (loss of serial data), the IPC will illuminate the ABS indicator lamp. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Lamp Test ABS Light: Testing and Inspection Lamp Test This test allows the user to control all the warning/indicator lamps associated with the IPC. It can be used to check the lamp circuits and the serial data link to the IPC. When using this test, all the indicators associated with the IPC will be ON. This test is similar to a BULB CHECK. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Lamp Test > Page 10720 ABS Light: Testing and Inspection Symptom Diagnosis ABS Warning Lamp Always ON, No DTC's Stored Table A : ABS Warning Indicator On With No DTCs Set ABS/ETS Circuit Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Lamp Test > Page 10721 CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the Electronic Brake Control Module (EBCM) and the Instrument Panel Cluster (IPC). A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wiring connections or physical damage to the wiring harness. ABS Warning Indicator Inoperative Table B ABS Warning Indicator Inoperative Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Lamp Test > Page 10722 ABS/ETS Circuit Schematic CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wiring connections or physical damage to the wiring harness. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10727 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10728 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10729 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10730 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10731 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10732 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10733 Audible Warning Device: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10734 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10735 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10736 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10737 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10738 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10739 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10740 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10741 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10742 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10743 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10744 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10745 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10746 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10747 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10748 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10749 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10750 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10751 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10752 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10753 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10754 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10755 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10756 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10757 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10758 Audible Warning Device: Electrical Diagrams Lights-ON Ignition/Fasten Belts (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10759 Lights-ON Ignition/Fasten Belts (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10760 Lights-ON Ignition/Fasten Belts (Part 3 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10761 Lights-ON Ignition/Fasten Belts (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10762 Lights-ON Ignition/Fasten Belts (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10763 Lights-ON Ignition/Fasten Belts (Part 3 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information Audible Warning Device: Description and Operation General Information The Audible Wainings System is controlled by the Multi-Function Alarm Module and sounds a chime to bring attention to several conditions. These conditions are: 1. Key is in the Ignition Cylinder (with door open). 2. Seat Belt is not fastened. 3. Headlights are on (with door open). The Multi-Function Alarm Module also controls a battery run down protection feature. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10766 Audible Warning Device: Description and Operation Instrument Panel Cluster INSTRUMENT PANEL CLUSTER (IPC) Instrument Panel Cluster (IPC) Instrument Panel Cluster (IPC) The Vehicle Theft Deterrent's logic is contained within the Instrument Panel Cluster (IPC). The IPC will read an R-Code from the PASSLOCK Lock Cylinder within a certain timing window. If the R-Code is correct and within the timed window, the IPC will PASS THEFT and will transmit it's coded password to the Powertrain Control Module (PCM). There are two ways the IPC may enter a theft mode; a bad timing cycle, or a bad R-Code. If the R-Code is not read within the window, the Vehicle Theft Deterrent will go into a SHORT TAMPER MODE during which the it will not allow the car to operate for four (4) seconds and the telltale will flash. After three (3) consecutive failed timings, the Vehicle Theft Deterrent (VTD) will go into it's LONG TAMPER MODE. In this mode, the telltale will flash and the Fuel Injectors will be shut off for approximate ten (10) minutes . Please note, before ANY TAMPER MODE the vehicle may start; however the car will quickly stall. If the IPC receives the wrong R-Code, the VTD will immediately go into it's LONG TAMPER MODE in which the vehicle's fuel injection will be locked-out for ten (10) minutes as described above. The THEFT SYSTEM Telltale will flash while the VTD is in ANY TAMPER MODE. The IPC continually checks the operation of the VTD during the operation of the vehicle, If the THEFT SYSTEM Telltale lights continuously during vehicle operation, refer to the Vehicle Theft Deterrent's SYSTEM DIAGNOSIS. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10767 Audible Warning Device: Description and Operation Fasten Belts Chime With the Ignition Switch in "RUN," "BULB TEST" or START," voltage is applied through the ALARM Fuse to Connectorector C1 terminal "M" of the Multi-Function Alarm Module. With the LH front seat belt unbuckled, Connectorector C1 terminal "K" of the Multi-Function Alarm Module is grounded through the Seat Belt Switch. The fasten belts chime sounds for 4 to 8 seconds. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10768 Audible Warning Device: Description and Operation Fasten Belts Indicator The Fasten Belts Indicator is controlled by the Instrument Panel Cluster (IPC). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10769 Audible Warning Device: Description and Operation General Information The Audible Wainings System is controlled by the Multi-Function Alarm Module and sounds a chime to bring attention to several conditions. These conditions are: 1. Key is in the Ignition Cylinder (with door open). 2. Seat Belt is not fastened. 3. Headlights are on (with door open). The Multi-Function Alarm Module also controls a battery run down protection feature. Instrument Panel Cluster INSTRUMENT PANEL CLUSTER (IPC) Instrument Panel Cluster (IPC) Instrument Panel Cluster (IPC) The Vehicle Theft Deterrent's logic is contained within the Instrument Panel Cluster (IPC). The IPC will read an R-Code from the PASSLOCK Lock Cylinder within a certain timing window. If the R-Code is correct and within the timed window, the IPC will PASS THEFT and will transmit it's coded password to the Powertrain Control Module (PCM). There are two ways the IPC may enter a theft mode; a bad timing cycle, or a bad R-Code. If the R-Code is not read within the window, the Vehicle Theft Deterrent will go into a SHORT TAMPER MODE during which the it will not allow the car to operate for four (4) seconds and the telltale will flash. After three (3) consecutive failed timings, the Vehicle Theft Deterrent (VTD) will go into it's LONG TAMPER MODE. In this mode, the telltale will flash and the Fuel Injectors will be shut off for approximate ten (10) minutes . Please note, before ANY TAMPER MODE the vehicle may start; however the car will quickly stall. If the IPC receives the wrong R-Code, the VTD will immediately go into it's LONG TAMPER MODE in which the vehicle's fuel injection will be locked-out for ten (10) minutes as described above. The THEFT SYSTEM Telltale will flash while the VTD is in ANY TAMPER MODE. The IPC continually checks the operation of the VTD during the operation of the vehicle, If the THEFT SYSTEM Telltale lights continuously during vehicle operation, refer to the Vehicle Theft Deterrent's SYSTEM DIAGNOSIS. Fasten Belts Chime With the Ignition Switch in "RUN," "BULB TEST" or START," voltage is applied through the ALARM Fuse to Connectorector C1 terminal "M" of the Multi-Function Alarm Module. With the LH front seat belt unbuckled, Connectorector C1 terminal "K" of the Multi-Function Alarm Module is grounded through the Seat Belt Switch. The fasten belts chime sounds for 4 to 8 seconds. Fasten Belts Indicator The Fasten Belts Indicator is controlled by the Instrument Panel Cluster (IPC). Key-In-Ignition Chime Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > General Information > Page 10770 Voltage is applied at all times to Connector C2 terminal D of the Multi-Function Alarm Module through the INT LAMP Fuse. When the key is in the ignition and LH front door is open, Connector C1 terminal H and terminal E of the Multi-Function Alarm Module are grounded. This sounds the chime. Lamps-ON Chime The Multi-Function Alarm Module sounds the Lamps-on Chime when the following three conditions are met: 1. The Battery voltage at the Multi-Function Alarm Module connector C1 terminal D indicates that the Parklamps or Headlamps are on. 2. 0 volts at the Multi-Function Alarm Module connector C1 terminal M indicates that the Ignition Switch is in OFF, ACCY, or LOCK. 3. Ground at the Multi-Function Alarm Module connector C1 terminal H indicates that the LH Front Door is open. Battery Run Down Protection The Battery Run Down Protection Feature is made up of three independent features: The Parasitic Power Control, the Inadvertent Power Control, and the Courtesy Lights Control. Parasitic Power Control The Parasitic Power Control output of the Multi-Function Alarm Module supplies voltage to the Remote Control Door Receiver (RFA) Module and Radio. The output timer will shut off power to all of the above components where one of these two conditions occurs: ^ Vehicle travels for less than 24 Km (15 miles) since battery power is applied to the Multi-Function Alarm Module and is parked for 3 days following the last ignition cycle. ^ Vehicle travels for more than 24 Km (15 miles) since battery power is applied to the Multi-Function alarm module and is parked for 24 days following the last ignition cycle. Inadvertent Power Control The Inadvertent Power Control output of the Multi-Function Alarm Module supplies voltage to these lamps: Courtesy, Header, Rear Quarter, Vanity Mirror, Reading, I/P Compartment and Luggage Compartment. For more information, refer to Interior Lights. Courtesy Lights Control The Courtesy Lights Control output of the Multi-Function Alarm Module supplies ground to the Courtesy and Dome lamps. For more information, refer to Interior Lights. Power Output Diagnostic Mode There is a Power Output Diagnostic Module in the Multi-Function Alarm Module that can be used to run a quick check on the operation of the Parasitic Power Control, the Courtesy Lights Control and the Inadvertent Power Control outputs. It is activated after all of the following actions have been performed: ^ Close all doors. ^ Set Park Brake. ^ Turn Interior Lights on using Panel Dimmer Switch. ^ Turn Ignition Switch to "RUN" and, before 15 seconds pass, perform these steps. Open the RH front door - Cycle the Headlamp Switch from "PARK" to "OFF" 3 times. During normal operations (no trouble found), the Multi-Function Alarm Module will flash the Interior Lights until the ignition switch is turned to "OFF." In the event of an internal short is found in the Multi-Function Alarm Module, the module will chime as follows: ^ 1 chime every 3 seconds - Inadvertent output failure ^ 2 chimes every 3 seconds - Courtesy output failure ^ 3 chimes every 3 seconds - Parasitic output failure Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures Audible Warning Device: Diagnostic Trouble Code Tests and Associated Procedures System Check System Diagnosis - Audible Warning System ^ Perform the System Check and refer to the Symptom Table for the appropriate diagnostic procedures. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10773 Audible Warning Device: Symptom Related Diagnostic Procedures Chart #1 All Warning Chimes Inoperative Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10774 Chart #2 Key-In-Ignition Chime Does Not Operate Properly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10775 Chart #3 Fasten Belts Chime Does Not Operate Properly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10776 Chart 1, Part 1 Of 2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10777 Chart 1, Part 2 Of 2 Chart 2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10778 Chart 3 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10779 Chart 4 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10780 Chart 5 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10781 Chart 6 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10782 Chart 7 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 10783 Symptom Table Troubleshooting Hints - Audible Warning System PERFORM BEFORE BEGINNING SYSTEM DIAGNOSIS: NOTE: The Multi-Function Alarm Module will "go to sleep" 3 or 20 minutes after "key off" depending if the vehicle has traveled over 24 Km (15 miles). Until the Multi-Function Alarm Module "goes to sleep," it will draw 60 - 80 mA. Once the Multi-Function Alarm Module "goes to sleep," the amperage draw will drop to 3 - 15 mA. ^ Check the ALARM Fuse, INSTR/PCM Fuse, and the INT LAMP Fuse by visual inspection. ^ Check for a broken (or partially broken) wire inside of the insulation which could cause system failure but prove "GOOD" in a continuity/voltage check. (refer to "General Troubleshooting Procedures" under Diagrams/Diagnostic Aids). ^ Check for proper installation of aftermarket electronic equipment which may affect the integrity of other systems (refer to "General Troubleshooting Procedures" under Diagrams/Diagnostic Aids"). ^ Refer to System Diagnosis. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10788 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10789 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10790 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10791 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10792 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10793 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10794 Audible Warning Device Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10795 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10796 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10797 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10798 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10799 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10800 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10801 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10802 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10803 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10804 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10805 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10806 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10807 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10808 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10809 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10810 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10811 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10812 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10813 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10814 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10815 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10816 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10817 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10818 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10819 Audible Warning Device Control Module: Electrical Diagrams Refer to Diagrams under Audible Warning Device. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10820 Audible Warning Device Control Module: Testing and Inspection Refer to Audible Warning Device for all Audible Warning System diagnostic information. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10821 Audible Warning Device Control Module: Service and Repair MULTI-FUNCTION ALARM ASSEMBLY Description REMOVE OR DISCONNECT 1. Negative battery cable. 2. Left sound insulator. 3. Nuts from alarm module. 4. Multi-function alarm assembly from convenience center. INSTALL OR CONNECT 1. Multi-function alarm assembly to convenience center. Tighten ^ Nuts to 6 Nm (53 lb. in.) 2. Nuts to alarm module. 3. Left sound insulator. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10826 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10827 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10828 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10829 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10830 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10831 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10832 Brake Warning Indicator: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10833 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10834 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10835 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10836 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10837 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10838 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10839 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10840 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10841 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10842 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10843 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10844 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10845 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10846 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10847 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10848 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10849 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10850 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10851 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10852 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10853 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10854 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10855 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10856 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10857 Brake Warning Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Antilock Brake System Brake Warning Indicator: Description and Operation Antilock Brake System The antilock brake system uses two indicator lamps, a red "BRAKE" warning lamp and an amber "ANTLOCK" lamp, both located in the instrument panel cluster. Under normal conditions, these lamps should activate as follows: 1. When ignition is turned to the "RUN" position, p~rior to starting the engine, the amber 'ANTILOCK" lamp should turn "ON". 2. As the engine is cranked, the red "BRAKE" lamp and the amber "ANTILOCK" lamp should come 3. When the engine is started, both lamps should be "OFF". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Antilock Brake System > Page 10860 Brake Warning Indicator: Description and Operation Standard Brake System The BRAKE Indicator lamp has two functions. First, it will light whenever the park brake is set. Second, a switch built into the brake master cylinder reservoir will signal the EBCM if the brake fluid level drops below a safe level. The EBCM will command the indicator "ON" via serial data with the IPC. In addition, the indicator is commanded "ON" when the EBCM is initially powered up (ignition m RUN" position). With the ignition in the "OFF/UNLOCK" or "CRANK" positions (loss of EBCM serial data), the telltale will also be illuminated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation Check Gauges Lamp: Description and Operation The CHECK GAGES telltale is controlled by the IPC. The IPC will illuminate this telltale when either the Engine coolant temperature gage reaches it's warning level or the Fuel Gage has reached a low level. As a bulb check procedure, the IPC will illuminate this telltale for three seconds when the IPC is powered up (ignition in OFF/UNLOCK," "RUN," OR "CRANK" positions). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Customer Interest: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Cigarette Lighter: Customer Interest Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-45-005 > Nov > 99 > Accessory Receptacle/Cigar Lighter - Inoperative Cigarette Lighter: All Technical Service Bulletins Accessory Receptacle/Cigar Lighter - Inoperative File In Section: 08 - Body and Accessories Bulletin No.: 99-08-45-005 Date: November, 1999 TECHNICAL Subject: Accessory Receptacle/Cigar Lighter is Inoperative (Check Aftermarket Device Plug for Short to Ground) Models: 1995-2000 Passenger Cars and Trucks Condition Some customers may comment that the cigar lighter or the accessory receptacle is inoperative; or that the internal fuse (within the plug on an aftermarket device), blows intermittently. Cause Certain aftermarket devices have a newly designed power plug with an internal mini fuse. The mini fuse may have an external terminal (which may be used to externally check the fuse). If the mini fuse external test terminal is not recessed into the mini fuse body, it may come in contact with the shell of the vehicle receptacle and cause the fuse (of either the vehicle or the aftermarket device), to blow intermittently. Correction Test the aftermarket device plug for short to ground. The following step may be performed at the customer's expense. As this is not a defect in material, design or workmanship of the vehicle, it would be the owner's responsibility. 1. Place a piece of tape over the mini fuse terminal temporarily. 2. Explain to the customer that the fuse for the device must have no exposed terminals, and that finding one would be his responsibility. 3. Refer the customer to the manufacturer of the aftermarket device for a new plug. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cigarette Lighter: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Shift Flare/DTC's Set/SES Lamp ON Bulletin No.: 03-07-30-021A Date: November 19, 2003 TECHNICAL Subject: Neutral Flare and/or RPM Flare While In Drive, No 1-2 Upshift, Service Engine Soon (SES) Light Illuminated, Diagnostic Trouble Codes (DTCs) P1810, DTC P1815 Set (Reprogram the Powertrain Control Module (PCM), Replace Transmission Fluid Pressure (TFP) Manual Valve Position Switch) Models: 1995-2003 Chevrolet Cavalier 1997-2003 Chevrolet Malibu 1999-2003 Oldsmobile Alero 1995-2003 Pontiac Sunfire 1998-2003 Pontiac Grand Am with 4T40E Transmission (RPO MN4) or 4T45E Transmission (RPO MN5) Supercede: This bulletin is being revised to add reprogramming of the PCM on 2003 V6 models. Please discard Corporate Bulletin Number 03-07-30-021 (Section 07-Transmission/Transaxle) Condition Some customers may comment on a neutral flare and/or RPM increase while in drive or no 1-2 upshift and/or the Service Engine Soon (SES) telltale may be illuminated. On 1995-2002 model vehicles, the Powertrain Control Module (PCM) may set a DTC P1810 while on 2003 model vehicles, the PCM may set a DTC P1815. Cause The cause may be the transmission fluid pressure (TFP) switch (also known as the pressure switch manifold (PSM)). It will be referred to as the TFP switch in this bulletin. Correction Follow the diagnosis and service procedure below to correct this condition. VIN BREAKPOINTS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cigarette Lighter: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10882 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cigarette Lighter: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10883 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cigarette Lighter: > 71-65-37 > May > 97 > Engine Controls - Revised DTC P0705 PABC Data Table Transmission Position Switch/Sensor: All Technical Service Bulletins Engine Controls - Revised DTC P0705 PABC Data Table File In Section: 6E - Engine Fuel & Emission Bulletin No.: 71-65-37 Date: May 1997 SERVICE MANUAL UPDATE Subject: Section 6E - Driveability and Emissions - Revised DTC P0705 Scan Tool Trans Range PABC Data Table Models: 1996-97 Buick Skylark 1996-97 Chevrolet Cavalier, Malibu 1996-97 Oldsmobile Achieva 1996-97 Pontiac Grand Am, Sunfire with 2.2L and 2.4L Engine (VINs 4, T - RPOs LN2, LD9) This bulletin is being issued to revise the DTC P0705 Trans Range PABC Data Table for the following service manuals: ^ 1997 GMP/97-L/N-2 ^ 1997 GMP/97-N-2 ^ 1997 GMP/97-J-2 Transaxle Range Switch Valid Input Combinations The table revises the DTC P0705 PABC Display table: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cigarette Lighter: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10893 1. If servicing a 2003 Alero, Grand Am, or Malibu with a V6 (RPO LG8 or LA1) for a DTC P1815 built prior to the VIN Breakpoints listed in the table above, REPROGRAM the PCM with the calibrations listed, prior to replacing the TFP switch. Important: Before installing the new TFP switch, inspect the date code stamped in the switch. The date code MUST BE 2308 or higher. Refer to the illustration above. 2. Replace the TFP switch. 3. Clear the code and road test the vehicle. 4. If additional diagnosis is required to correct this condition, refer to: ^ For diagnosis of DTC P1810, refer to DTC P1810. ^ For diagnosis of DTC P1815, refer to DTC P1815. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cigarette Lighter: > 03-07-30-021A > Nov > 03 > A/T - Shift Flare/DTC's Set/SES Lamp ON > Page 10894 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Component Locations Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Component Locations > Page 10901 Cigarette Lighter: Connector Locations LH I/P And Console Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10904 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10905 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10906 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10907 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10908 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10909 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10910 Cigarette Lighter: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10911 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10912 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10913 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10914 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10915 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10916 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10917 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10918 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10919 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10920 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10921 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10922 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10923 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10924 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10925 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10926 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10927 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10928 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10929 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10930 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10931 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10932 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10933 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10934 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 10935 Cigarette Lighter: Service and Repair Description Remove or Disconnect 1. Cluster Trim Plate. 2. Electrical connector. 3. Base to retainer, counterclockwise. 4. Lighter Housing from trim plate. Install or Connect 1. Lighter Housing to trim plate. 2. Base to retainer. 3. Electrical connector. 4. I/P cluster trim plate. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation The Low Coolant Switch is located in the coolant surge tank. The IPC contains the Low Coolant Indicator. The IPC lights this telltale when commanded to by the PCM. If the coolant level in the surge tank is low, the low coolant indicator will turn on and will remain on until the Ignition Switch is turned off or the coolant level in the surge tank is restored to a normal level. For a Bulb Check procedure, the IPC will light this telltale for 3 seconds when the IPC is initially powered up (ignition in "OFF/UNLOCK," "RUN," or "CRANK" positions) regardless of the serial data signal. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel to the straight ahead position. ^ Remove the key from the ignition switch. 1. The AIR BAG fuse from the I/P fuse block. 2. The I/P sound insulator - (LH). 3. The Connector Position Assurance (CPA) and the driver yellow 2-way connector located at the base of the steering column. 4. The Connector Position Assurance (CPA) and the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10944 IMPORTANT With the AIR BAG fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is normal operation and does not indicate a SIR system malfunction. Enabling the SIR System INSTALL OR CONNECT ^ Remove the key from the ignition switch. 1. The passenger yellow 2-way connector and the CPA located near the base of the steering column. 2. The driver yellow 2-way connector and the CPA located at the base of the steering column. 3. The I/P sound insulator - (LH). 4. The AIR BAG fuse to the I/P fuse block. Staying well away from both air bags, turn the ignition switch to the RUN position. Verify that the AIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10945 BAG warning lamp flashes seven times and then stays off. If the AIR BAG warning lamp does not operate as described, perform the SIR DIAGNOSTIC SYSTEM CHECK. See: Restraint Systems/Air Bag Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Board / Instrument Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10946 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn off the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR System prevents deploying of the air bags from the reserve energy supply power. Refer to Disabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead > Page 10953 LH I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Jamb Switch Connector RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Jamb Switch Connector > Page 10958 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 73-83-15 > Apr > 97 > Instruments - Fuel Gauge Responds Slowly After Fueling Fuel Gauge: Customer Interest Instruments - Fuel Gauge Responds Slowly After Fueling File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-83-15 Date: April, 1997 INFORMATION Subject: Fuel Gauge Responds Slowly After Fueling Models: 1996-97 Passenger Cars and Trucks (Except Geo) Some owners may comment that the fuel gage reading responds very slowly after fueling the vehicle. The needle may take up to 8 minutes before reaching the "FULL" mark. Most 1997 vehicles, and some 1996, contain a damping function in the fuel gauge circuit. This allows the gauge to respond slowly to changes in tank level, preventing the large needle swings when the vehicle is driven around comers or during acceleration/deceleration. This is called an "anti-slosh" function. The anti-slosh function does not operate immediately after the ignition is first turned on. Therefore, the above condition will only occur if the ignition is left on during fueling. The owner can get the correct reading immediately by turning the ignition key off, then on. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 73-83-15 > Apr > 97 > Instruments - Fuel Gauge Responds Slowly After Fueling Fuel Gauge: All Technical Service Bulletins Instruments - Fuel Gauge Responds Slowly After Fueling File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-83-15 Date: April, 1997 INFORMATION Subject: Fuel Gauge Responds Slowly After Fueling Models: 1996-97 Passenger Cars and Trucks (Except Geo) Some owners may comment that the fuel gage reading responds very slowly after fueling the vehicle. The needle may take up to 8 minutes before reaching the "FULL" mark. Most 1997 vehicles, and some 1996, contain a damping function in the fuel gauge circuit. This allows the gauge to respond slowly to changes in tank level, preventing the large needle swings when the vehicle is driven around comers or during acceleration/deceleration. This is called an "anti-slosh" function. The anti-slosh function does not operate immediately after the ignition is first turned on. Therefore, the above condition will only occur if the ignition is left on during fueling. The owner can get the correct reading immediately by turning the ignition key off, then on. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 10977 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 10978 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 10984 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 10985 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Page 10986 Fuel Gauge: Description and Operation An electrical fuel gage system is used, consisting of an instrument panel cluster gage and a fuel tank sending unit. The fuel gage indicates the quantity of fuel in the tank when the Ignition Switch is in the "RUN" position. When the Ignition Switch is turned to the "OFF," "LOCK," "START" or "ACCESSORY" position, the pointer may come to rest at any position. A fuel tank unit in the fuel tank changes resistance with fuel level. The resistance varies from approximately 0 ohms at empty to 90 ohms at full. The IPC reads the resistance value and assigns an appropriate value between 0 (empty) and 255 (full) counts where it is transmitted to the Powertrain Control Module (PCM) via serial data. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10991 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10992 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10993 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10994 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10995 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 10996 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation > DRL Indicator Headlamp Reminder Indicator: Description and Operation DRL Indicator In Pontiac cars, the high beam and low beam headlamps are run in series to serve as daytime running lights. In Chevrolet cars, the high beam headlamps are run in series. The park lamps, tail lamps, license plate lamps and side marker lamps do not operate when the daytime running lights are "ON". The operation of daytime running lights is controlled by the IPC. The DRL Indicator on the Instrument Panel Cluster glows when the engine is running and the park lamp or headlamp switch is in the "OFF" position with the Park Brake off. When the headlamps (or park lamps) are turned on, the indicator will turn off. If the vehicle is started with the Park Brake on, the daytime running lights will not operate until the Park Brake is released. This feature allows the car to idle while parked, without the daytime running lights being ON." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation > DRL Indicator > Page 11001 Headlamp Reminder Indicator: Description and Operation High Beam (Blue) Indicator The High Beam Indicator will illuminate during flash-to-pass or whenever headlights are on and high beams are selected. This indicator is controlled by the IPC. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Disabling the SIR System REMOVE OR DISCONNECT ^ Turn the steering wheel to the straight ahead position. ^ Remove the key from the ignition switch. 1. The AIR BAG fuse from the I/P fuse block. 2. The I/P sound insulator - (LH). 3. The Connector Position Assurance (CPA) and the driver yellow 2-way connector located at the base of the steering column. 4. The Connector Position Assurance (CPA) and the passenger yellow 2-way connector located near the base of the steering column. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11007 IMPORTANT With the AIR BAG fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is normal operation and does not indicate a SIR system malfunction. Enabling the SIR System INSTALL OR CONNECT ^ Remove the key from the ignition switch. 1. The passenger yellow 2-way connector and the CPA located near the base of the steering column. 2. The driver yellow 2-way connector and the CPA located at the base of the steering column. 3. The I/P sound insulator - (LH). 4. The AIR BAG fuse to the I/P fuse block. Staying well away from both air bags, turn the ignition switch to the RUN position. Verify that the AIR Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11008 BAG warning lamp flashes seven times and then stays off. If the AIR BAG warning lamp does not operate as described, perform the SIR DIAGNOSTIC SYSTEM CHECK. See: Restraint Systems/Air Bag Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11009 Air Bag(s) Arming and Disarming: Service and Repair General Service Precautions CAUTION: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Use the following procedure to temporarily disable the SIR system. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply. When the vehicle power is insufficient to cause deployment of the air bags, the reserve energy supply provides the deployment power. Deployment power is available for as much as 10 minutes after disconnecting the vehicle power by any of the following methods: ^ You turn off the ignition switch. ^ You remove the fuse that provides power to the SDM. ^ You disconnect the vehicle battery from the vehicle electrical system. Disabling the SIR System prevents deploying of the air bags from the reserve energy supply power. Refer to Disabling the SIR System. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Instrument Panel Bulb > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Instrument Panel Bulb > Component Information > Locations > Page 11013 Instrument Panel Bulb: Service and Repair To change any instrument panel bulb, including instrument warning or cluster illumination, use the following procedure: Remove or Disconnect 1. Instrument Panel Cluster. 2. Twist bulb/socket assembly counterclockwise to remove. Install or Connect 1. Bulb into socket and socket into cluster, turn clockwise to tighten. 2. Cluster into I/P. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier <--> [Instrument Cluster / Carrier] > Instrument Panel Circuit Board > Component Information > Technical Service Bulletins > Instrument Panel Cluster - Revised Replacement Instrument Panel Circuit Board: Technical Service Bulletins Instrument Panel Cluster - Revised Replacement File In Section: 08 - Body and Accessories Bulletin No.: 01-08-49-009 Date: June, 2001 SERVICE MANUAL UPDATE Subject: Revised Instrument Panel Cluster (IPC) Replacement Models: 1995 Chevrolet Cavalier with 2.3L Engine (VIN D - RP0 LD2) 1995 Pontiac Sunfire with 2.3L Engine (VIN D - RP0 LD2) 1996-1999 Chevrolet Cavalier 1996-1999 Pontiac Sunfire This bulletin is being issued to add a step to the Instrument Panel Cluster (IPC) Replacement procedure in the Instrument Panel and Console sub-section of the Service Manual. Please add this information to your Service Manual. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. It is necessary to reprogram the theft deterrent system after IPC replacement. The final step of the installation procedure of the Instrument Panel Cluster (IPC) Replacement procedure should read "Disengage the theft deterrent tamper mode. Refer to PASSLOCK Changing - Components Description in Theft Deterrent." DISCLAIMER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation The CHECK ENGINE (Malfunction Indicator Lamp) Indicator in the Instrument Panel Cluster. The CHECK ENGINE Indicator will illuminate with the Ignition Switch in "RUN" position and engine off. The light will stay on a short time after the engine starts and should go out in 1 to 5 seconds. If the light stays on, or comes on while driving, service to the emission control system may be required. The indicator is controlled via a hardwired connection with the PCM and the IPC. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation The Check Oil Indicator is controlled by the IPC as commanded by the PCM via serial data. The oil level is monitored by the PCM with an Oil Level Switch. When the PCM determines a low oil condition, it commands the indicator "ON". As a bulb check procedure, the PCM will command this telltale "ON" when the IPC and PCM are powered up (ignition m OFF/UNLOCK," "RUN," or "CRANK" position) and the engine is not running. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The engine Oil Pressure Indicator is controlled by the IPC as commanded by the PCM via serial data. The Oil Pressure Indicator will also light when the engine is running if engine oil pressure drops below approximately 13.8 pa (2 psi). As a bulb check procedure, the PCM will command this telltale "ON" for when the IPC and PCM are powered up (ignition in "OFF/UNLOCK," "RUN," or "CRANK" position) and the engine is not running. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11035 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11036 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > Component Information > Locations Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 63-50-15B > Mar > 98 > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 63-50-15B > Mar > 98 > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11048 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Brake Warning Lamp: > 63-50-15B > Mar > 98 > Customer Interest for Parking Brake Warning Lamp: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11049 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11058 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11059 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11065 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11066 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Page 11067 LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11073 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11074 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11075 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11076 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11077 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11078 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11079 Audible Warning Device Control Module: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11080 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11081 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11082 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11083 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11084 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11085 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11086 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11087 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11088 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11089 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11090 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11091 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11092 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11093 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11094 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11095 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11096 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11097 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11098 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11099 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11100 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11101 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11102 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11103 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11104 Audible Warning Device Control Module: Electrical Diagrams Refer to Diagrams under Audible Warning Device. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 11105 Audible Warning Device Control Module: Testing and Inspection Refer to Audible Warning Device for all Audible Warning System diagnostic information. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 11106 Audible Warning Device Control Module: Service and Repair MULTI-FUNCTION ALARM ASSEMBLY Description REMOVE OR DISCONNECT 1. Negative battery cable. 2. Left sound insulator. 3. Nuts from alarm module. 4. Multi-function alarm assembly from convenience center. INSTALL OR CONNECT 1. Multi-function alarm assembly to convenience center. Tighten ^ Nuts to 6 Nm (53 lb. in.) 2. Nuts to alarm module. 3. Left sound insulator. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The Seat Belt Indicator is controlled by the IPC via serial data based on status of the Seat Belt Switch. The status of the Seat Belt Switch is received from the SDM. The indicator will light when ignition is in the "RUN" or "CRANK" positions and the driver's safety belt is not fastened. Also, the Multi-Function Alarm Module will sound when the Ignition Switch is turned to the "RUN" position with the driver's safety belt not fastened. The chime will silence as soon as the driver's safety belt is fastened or within six seconds, whichever occurs first. The Seat Belt Indicator will light steady for 20 seconds and then flash for an additional 55 seconds. The indicator will go out as soon as the driver's safety belt is fastened or the light times out, whichever occurs first. Please note that unbuckling the seat belt will result in this sequence repeating. During a loss of serial data (ignition in OFF/UNLOCK"), the telltale will light steady. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead > Page 11117 LH I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch Connector RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch Connector > Page 11122 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure Fuel Gauge Sender: Technical Service Bulletins Fuel Level Sensor - Replacement Procedure File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-83-07 Date: March, 1998 Subject: Fuel Level Sensor Replacement Procedure Models: 1997-98 Passenger Cars and Light Duty Trucks (Listed in Application Chart) INFORMATION This bulletin is being issued to clarify that, when fuel gauge diagnosis per the Service Manual indicates the cause to be the fuel level sensor, complete fuel sender assembly replacement is NOT required. Available fuel level sensor service packages are indicated in the application charts and should be installed following applicable Service Manual procedures and those provided in the service packages. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 11127 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 11128 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 11129 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 11130 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 11131 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Level Sensor - Replacement Procedure > Page 11132 Parts Information See the charts for listed for applicable part numbers. Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the tables. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11141 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11142 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables Technical Service Bulletin # 73-50-18 Date: 980101 Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables File In Section: 5 - Brakes Bulletin No.: 73-50-18 Date: January, 1998 Subject: Rear Brakes Drag/Heat Up (Adjust Brake Lamp Switch and/or Replace Park Brake Cables) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire 1996-97 Pontiac Grand Am Built prior to VIN Breakpoints as shown. Condition Some owners may comment that the rear brakes may drag/heat up or rear of car is squatting due to aggressive rear brake. Cause Rear brake drag may be caused by incomplete release of the parking brake cable system. Parts Information Description Old P/N New P/N Parking Brake Cable 22636670 22603399 Assembly - Front Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11148 For vehicles repaired under warranty, use the table. Correction Diagnosis of the condition should be carried out as follows: 1. Check and/or Adjust Brake Lamp Switch By: Remove a. Driver side sound insulator. b. Electrical connection from brake switch. c. Adjust brake switch as follows: 1995 - Pull brake pedal upward with approximately 40 pounds of force. Switch may move in retainer providing proper adjustment. No noise indicates adjustment was correct. 1996-97 - Some late 1996 and 1997 J-models may have a new style brake switch. To adjust this new style switch, rotate stop lamp switch counter-clockwise approximately 45. in retainer until switch stops. Pull switch toward rear of vehicle and then push towards front of vehicle until switch bottoms out against brake pedal (see "Important" statement below) and switch actuator is fully depressed. Snap brake switch into retainer by turning clockwise 45. until a click is heard. Important: Brake pedal must be in rest position during above adjustment procedure. Install a. Electrical connection to brake switch. b. Driver side sound insulator. REQUIRED ADJUSTMENT - After adjustment, proceed to Step 3 (checking front and rear brakes) and then Step 2. BRAKE SWITCH FOUND PROPERLY - Proceed to Step 2. 2. Elevate Rear Wheels and Check For Low Turning Effort By Hand: FREE - Cycle park brake 3-4 times and re-evaluate drag. If drag cannot be duplicated under customer conditions of usage, environment, etc., return to service. NOT FREE - Proceed to Step 3. 3. On Wheels That Are Dragging, remove wheel and brake drum for diagnosis. Inspect the drum/linings for signs of overheating (cracked or crumbling brake lining, blue coloration of brake drum or brake shoe web, unusual odor, etc. Damaged linings and drum(s) should be replaced and Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Warning Switch: > 73-50-18 > Jan > 98 > Brakes - Rear Brakes Drag/Heatup, Parking Brake Cables > Page 11149 the other brake components should be inspected and serviced for damage (i.e., wheel bearing assembly, parking brake cable, wheel cylinder, etc.). OVERHEATED - After mechanical repair, return to Step 2. NOT OVERHEATED - Proceed to Step 4. 4. With Park Brake Lever Released, pull back the front cable at the rear axle connection. This will create "slack" in the system that had been taken up by the self-adjust mechanism. This places the cable in the fully released position. Recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to evaluate front portion of the park brake system. NOT FREE - Concern may be in rear brake assembly or rear park brake cable(s). Proceed to Step 5. 5. Review Mechanical Operation of Rear Brakes and Cables to look for discrepant or mis-assembled part(s). Inspect rear brake cable for physical condition, correct routing into and inside the rear brake assemblies and for freedom of interference with adjacent parts. With drums installed, check for proper actuation of the shoes both hydraulically and with the park brake lever. The current rear park brake cable is P/N 22651234 and is identified by red tape. If replacement is necessary, verify that the cable being installed is the correct part number. Check the operation of the park brake system by fully applying it 3-4 times (to fully adjust) and recheck wheel turning effort to insure wheel turns easily by hand. FREE - Proceed to Step 6 to re-evaluate the front portion of the park brake system. NOT FREE - review mechanical operation of brake and/or cable to look for discrepant or mis-assembled parts. 6. Inspect Front Park Brake Cable and Lever Assembly for proper installation and operation. Cable should be inspected for pinches (especially near driver's inboard seat track and rear console bracket), kinks, nicks, or cuts in cable strand coating, etc. The parking brake cable wire strand is coated with a plastic material that slides against nylon seals inside the conduit end fittings. This plastic coating is for corrosion protection and reduced parking brake effort. Handling of these cables during servicing of the parking brake system requires a little extra care. Damage to the plastic coating will reduce corrosion protection and if the damaged area passes through the seal, it may damage the seal and cause the cable to snag and not fully release. Contacting the coating with sharp-edged tools or with sharp surfaces of the vehicle underbody should be avoided. Important: Plastic coated parking brake cables do not need periodic lubrication. To check operation of the cable, disconnect both the ends of the front parking brake cable to verify the cable strand moves freely by hand from either end (approximately 5-10 lb. force): DAMAGE/INSUFFICIENT OPERATION - Replace front cable, P/N 22603399. After replacement, return to Step 2 for verification. 7. The Park Brake Lever Should Be Inspected for proper operation and for the self-adjust feature. It may be checked by pulling the cables down at the rear axle as in Step 4 and cycling the system 3-4 times. While cycling the system, hold the release button in as this will allow you to hear the adjustment "clicks." After re-installing the console assembly, recheck for brake drag and possibly a feeling of "tightness" at the lever assembly. DRAGGING AND/OR "TIGHTNESS" OF OPERATION - Recheck front and/or rear park brake cables for possible mis-routing or cable damage. Repair and re-evaluate with Step 2. FREE/NORMAL - Verify no drag condition exists and return vehicle to service. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Technical Service Bulletins > Page 11150 LH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation The Upshift Indicator is illuminated to indicate optimum shift points for maximum fuel economy. When this light is on, shift transaxle to the next higher gear range, if conditions permit. This indicator is controlled by the IPC as commanded by the PCM via serial data. This telltale will not turn on as result of serial data loss (ignition in OFF/UNLOCK"). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information Speedometer Head: Technical Service Bulletins Instruments - Speedometer Accuracy Information INFORMATION Bulletin No.: 08-08-49-011B Date: September 05, 2008 Subject: Information On Speedometer Accuracy Models: 1997-1999 GM Passenger Cars And Trucks 2004-2009 Cadillac XLR 2005-2009 Chevrolet Corvette 2007-2009 GMC Acadia Supercede: This bulletin is being revised to add the GMC Acadia. Please discard Corporate Bulletin Number 08-08-49-011A (Section 08 - Body and Accessories). The speedometer used on most GM vehicles are of the Air-Core design. This is a moving needle operated by a magnetic coil. Because there is no direct mechanical linkage, there is some variation in accuracy that cannot be eliminated. Digital readout devices, such as some speedometer displays and Head-Up Displays (HUD), are direct readouts of the Vehicle Speed Sensor (VSS) and their accuracy is much greater. Tire size, tread life and inflation may cause some variation in the readings. In addition, the Tech 2(R) reads the VSS directly and is quite accurate. Questions on speedometer accuracy can usually be resolved by comparing the speedometer reading to the Tech 2 while driving. The table shown above lists allowable speedometer variations. Any Air-Core speedometer that reads within these limits should not be returned for service. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11158 Speedometer Head: Technical Service Bulletins Instruments - New Diagnostic Tables For VSS Circuits File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-81-32 Date: May, 1997 SERVICE MANUAL UPDATE Subject: Section 8A - Electrical Diagnosis - New Diagnostic Tables for Vehicle Speed Sensor Signal Circuit Models: 1996-97 Buick Skylark 1996 Chevrolet Beretta, Corsica 1996-97 Chevrolet Cavalier 1997 Chevrolet Malibu 1996-97 Oldsmobile Achieva 1997 Oldsmobile Cutlass 1996-97 Pontiac Grand Am, Sunfire This bulletin is being issued to add new diagnostic tables to Section 8A of the Service Manual. The tables included describe the diagnostic procedures for the diagnosis of the Vehicle Speed Sensor signal circuit from the Powertrain Control Module (PCM) to auxiliary devices. Please insert the included diagnostic tables into the Electrical Diagnosis Instrument Cluster section (Cell 80 J/L/N cars; Cell 81 L/N cars) of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11159 8A - 1 - 1 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11160 8A - 1 - 2 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11161 8A - 1 - 3 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11162 8A - 1 - 4 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11163 8A - 1 - 5 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11164 8A - 1 - 6 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11165 8A - 1 - 7 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11166 8A - 1 - 8 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11167 8A - 1 - 9 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11168 8A - 1 - 10 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11169 8A - 1 - 11 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11170 8A - 1 - 12 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11171 8A - 1 - 13 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11172 8A - 1 - 14 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11173 8A - 1 - 15 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11174 8A - 1 - 16 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11175 8A - 1 - 17 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11176 8A - 1 - 18 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11177 8A - 1 - 19 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11178 8A - 1 - 20 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11179 8A - 1 - 21 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11180 8A - 1 - 22 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11181 8A - 1 - 23 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11182 8A - 1 - 24 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11183 8A - 1 - 25 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11184 8A - 1 - 26 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11185 8A - 1 - 27 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Instruments - Speedometer Accuracy Information > Page 11186 8A - 1 - 28 ELECTRICAL DIAGNOSIS Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Page 11187 Speedometer Head: Description and Operation The speedometer is a road speed indicator. The base cluster contains a season (total mileage) odometer. The gage cluster is equipped with both a trip odometer and a season odometer. A vehicle speed sensor (VSS) (permanent magnet generator) located on the transaxle inputs to the powertrain control module (PCM) whenever the transaxle differential carrier turns. The PCM then buffers the VSS signal and transmits it to the IPC, the Electronic Brake Control Module (EBCM), and the Sensing Diagnostic Module (SDM) at 6452 pulses/km (4000 pulses/mile) via a hardwired connection (CKT 817). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation The tachometer indicates engine speed in Revolutions Per Minute (RPM) with the Ignition Switch in the "RUN" position. The PCM supplies information via serial data to the IPC which converts the data into an analog display. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation The engine coolant temperature gage indicates the temperature of the engine coolant with the Ignition Switch in the "RUN" position. A Coolant Temperature Sensor in the engine changes resistance with coolant temperature. As coolant temperature increases, the resistance of the sensor decreases. The PCM reads the resistance value and assigns an appropriate value between 0 and 255 counts where it is transmitted to the IPC via serial data. The IPC reads the count value and assigns a deflection value which causes the needle in the gages to turn. The gage will read from 37.8 deg C to 122 deg C (100 deg. F to 253 deg. F). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This switch activates a warning lamp in the instrument cluster if the engine overheats. With optional instrumentation, a temperature gage replaces the warning lamp. The temperature gage is driven with a transducer. The engine coolant temperature switch is not serviceable. If it is faulty, it should be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > General Description Traction Control Indicator Lamp: Description and Operation General Description CONDITIONS When the Electronic Brake Control Module (EBCM) needs to illuminate the "ETS OFF" or "LO TRAC" indicator lamps, it will transmit a signal (via serial data link) to the electronic Instrument Panel Cluster (IPC) and the IPC will illuminate the indicator lamp. The Amber "ETS OFF" Indicator Lamp - will be illuminated when ETS is disabled or when the driver switches ETS off with the ETS switch. As a bulb check procedure, the EBCM will command the ETS indicator lamp ON for 3 seconds when the EBCM receives power (ignition in RUN position). With the ignition in the OFF/UNLOCK or START positions (loss of serial data), the IPC will illuminate the ETS OFF indicator lamp. The Amber "LO TRAC" Indicator Lamp - will be illuminated to alert the driver of a low traction situation and to inform the driver the ETS is operating. As a bulb check procedure, the EBCM will command the LO TRAC indicator lamp ON for 3 seconds when the EBCM receives power (ignition in RUN or START positions). With the ignition in the OFF/UNLOCK position (loss of serial data), the IPC will illuminate the LO TRAC indicator lamp. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > General Description > Page 11201 Traction Control Indicator Lamp: Description and Operation Circuit Description Low Trac Indicator LOW TRAC (Option With 4 Speed Automatic Transaxle Only) The LOW TRAC Indicator is controlled by the IPC as commanded by the EBCM via serial data. The EBCM will command this indicator "ON" when the Enhanced Traction System is engaged. The EBCM will also command this telltale "ON" for three seconds when it is powered up (ignition in "RUN") as a bulb check procedure. During a loss of EBCM serial data communication (ignition m OFF/UNLOCK" or "CRANK"), the telltale will also he illuminated. Enhanced Traction System Telltale ETS OFF (Option With 4 Speed Automatic Transaxle Only) The Enhanced Traction System telltale is controlled by the IPC as commanded by the EBCM via serial data. This telltale will light when either the ETS is turned off or the ETS is unavailable due to a problem with the Anti-lock Brake System. The EBCM will command this telltale "ON" for three seconds when it is powered up (ignition m RUN") as a bulb check procedure. During a loss of EBCM serial data communication (ignition in "OFF/UNLOCK" or "CRANK"), the telltale will also be illuminated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set Traction Control Indicator Lamp: Testing and Inspection ETS Off Indicator ON With No DTCS Set Table-C - ETS Off, Indicator Lamp On With No DTCs Set ABS/ETS Circuit Schematic CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 11204 terminal to wiring connections or physical damage to the wiring harness. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 11205 Traction Control Indicator Lamp: Testing and Inspection ETS Off Warning Indicator Inoperative Table D ETS Off Warning Indicator Inoperative ABS/ETS Circuit Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection > ETS Off Indicator ON With No DTCS Set > Page 11206 CIRCUIT DESCRIPTION Two-way serial communication is sent back and forth between the EBCM and the IPC. A message from the IPC is sent to the EBCM within seven seconds after ABS initialization. A serial communication failure does not allow the proper lamp commands to be sent back to the IPC. DIAGNOSTIC AIDS The scan tool Serial Data Link (SDL) monitor used in this diagnostic is within the body portion of the scan tool. This requires exiting from the chassis portion of the scan tool to the main menu and entering into the body portion of the scan tool menu and selecting SDL MONITOR. With the SDL monitor (ABS to IPC mode), any message that is being transmitted on the serial data link can be observed. The frequency of the malfunction can be checked by using the ENHANCED DIAGNOSTIC function of the scan tool. Any circuitry that is suspected of causing the intermittent complaint should be thoroughly checked for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wiring connections or physical damage to the wiring harness. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation The Volts Indicator is controlled by both the PCM and the IPC. The IPC illuminates the light when it is initially started up (ignition in OFF/UNLOCK," "RUN," or "CRANK" positions) until the PCM sends the generator information via serial data, then the PCM may light the telltale. The PCM may light the telltale when the engine is running and the charging system voltage falls below 10 volts or more than 16 volts indicating service is required. During a loss of serial data (ignition in "OFF/UNLOCK"), this telltale will light steady. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Back Up Lamp Switch LH Rear Of Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Back Up Lamp Switch > Page 11220 Backup Lamp Switch: Locations Wire Harness to TCC and Neutral Start and Backup Light SW LH Front Of Engine/Transaxle LH Engine/Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 11221 Backup Lamp Switch: Service and Repair NOTICE: When removing or installing the backup light switch, DO NOT use a open end wrench. Use only a socket to avoid damage to the switch assembly. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Backup lamp connector. 3. Backup light switch assembly. INSTALL OR CONNECT 1. Backup light switch assembly. - Use pipe sealant GM P/N 1052080 or equivalent. Tighten Backup light switch to 33 N.m (24 lb. ft.). 2. Backup light connector. 3. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVE OR DISCONNECT 1. Bulb from socket by turning counter-clockwise and pulling out. INSTALL OR CONNECT 1. Bulb to socket by aligning tabs and turning clockwise. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 11229 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 11230 Top Of Rear Deck Lid Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11234 Brake Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11235 Brake Light Switch: Service and Repair Stop Light Switch REMOVE OR DISCONNECT 1. Driver side sound insulator. 2. Electrical connection. 3. Brake switch from retainer by grasping and pulling toward rear of vehicle. INSTALL OR CONNECT 1. Insert stop lamp switch into retainer until switch body seats on retainer. 2. Pull brake pedal upward against internal pedal stop. Switch will be moved in retainer providing proper adjustment. Proper switch adjustment is achieved when no clicks are heard when the pedal is pulled upward and the brake lights do not stay on without brake application. 3. Electrical connection. 4. Driver side sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Component Locations Top Of Rear Deck Lid Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Component Locations > Page 11240 LH And RH Top Of Rear Wheel Wells Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11243 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11244 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11245 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11246 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11247 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11248 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11249 Center Mounted Brake Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11250 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11251 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11252 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11253 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11254 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11255 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11256 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11257 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11258 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11259 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11260 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11261 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11262 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11263 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11264 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11265 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11266 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11267 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11268 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11269 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11270 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11271 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11272 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11273 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Locations > Courtesy/Reading Lamp and Switch LH and RH Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Locations > Courtesy/Reading Lamp and Switch LH and RH > Page 11278 Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11281 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11282 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11283 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11284 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11285 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11286 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11287 Courtesy Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11288 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11289 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11290 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11291 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11292 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11293 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11294 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11295 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11296 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11297 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11298 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11299 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11300 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11301 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11302 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11303 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11304 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11305 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11306 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11307 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11308 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11309 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11310 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11311 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 11316 Daytime Running Lamps Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Dimmer Switch Lead > Page 11323 LH I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > Customer Interest for Dome Lamp: > 638139 > Jan > 97 > Interior Dome Light - Stays On All The Time Dome Lamp: Customer Interest Interior Dome Light - Stays On All The Time File In Section: 8 - Chassis/Body Electrical Bulletin No.: 63-81-39 Date: January, 1997 Subject: Interior Dome Light Stays On All The Time (Reroute Wire Harness) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire Condition Some owners may comment on the interior dome light staying on all the time. Cause The front door jamb switch may be corroded due to the wire harness being incorrectly routed, causing a short in the circuit. Correction 1. Disconnect the front left hand door jamb switch (two way red connector, located inside the passenger compartment above the kick panel). If the interior light goes off after closing all doors and turning the ignition on, replace the door jamb switch. 2. After replacing the door jamb switch, seat it properly in the A pillar, then carefully pull the pigtail (with the red connector) inside the passenger compartment and tuck in a dry area. Do not leave the red connector Inside the A pillar area. 3. Repeat Steps 1 and 2 for front right hand door jamb switch, if the interior light is still on. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N2174 (RH) 0.2 hr N2175 (LH) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Dome Lamp: > 638139 > Jan > 97 > Interior Dome Light - Stays On All The Time Dome Lamp: All Technical Service Bulletins Interior Dome Light - Stays On All The Time File In Section: 8 - Chassis/Body Electrical Bulletin No.: 63-81-39 Date: January, 1997 Subject: Interior Dome Light Stays On All The Time (Reroute Wire Harness) Models: 1995-97 Chevrolet Cavalier 1995-97 Pontiac Sunfire Condition Some owners may comment on the interior dome light staying on all the time. Cause The front door jamb switch may be corroded due to the wire harness being incorrectly routed, causing a short in the circuit. Correction 1. Disconnect the front left hand door jamb switch (two way red connector, located inside the passenger compartment above the kick panel). If the interior light goes off after closing all doors and turning the ignition on, replace the door jamb switch. 2. After replacing the door jamb switch, seat it properly in the A pillar, then carefully pull the pigtail (with the red connector) inside the passenger compartment and tuck in a dry area. Do not leave the red connector Inside the A pillar area. 3. Repeat Steps 1 and 2 for front right hand door jamb switch, if the interior light is still on. Warranty Information For vehicles repaired under warranty, use: Labor Operation Labor Time N2174 (RH) 0.2 hr N2175 (LH) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > Page 11337 Dome Lamp: Locations Headliner Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch Connector RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch Connector > Page 11342 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 11348 Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 11349 Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11350 Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 11354 Folding Top Bypass Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 11355 Fog/Driving Lamp Switch: Description and Operation The fog lamp switch is located in the dimmer switch assembly. To turn on the fog lamps the ignition switch must be in the "RUN" position and the fog lamp switch must be in the "ON" position with the high beams off. When the fog lamps are turned on (head and park lamps off) the front and rear marker lamps, park lamps, tail lamps, license lamp and instrument panel lamps must also be on. When the high beam head lamps are selected, the fog lamps are turned off. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations LH Lower I/P Near Steering Column Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 11360 Turn/Hazard Flasher Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 11361 Hazard Warning Flasher: Service and Repair Description Remove or Disconnect 1. Convenience center. 2. Components from panel. Install or Connect 1. Install component into position and gently push forward until seated. 2. Convenience center. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 11365 Hazard Warning Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Headlamp Switch Lead Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Headlamp Switch Lead > Page 11375 LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11376 Headlamp Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation The High Beam Indicator will illuminate during flash-to-pass or whenever headlights are on and high beams are selected. This indicator is controlled by the IPC. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11384 Horn Relay: Service and Repair Description Remove or Disconnect 1. Convenience center. 2. Components from panel. Install or Connect 1. Install component into position and gently push forward until seated. 2. Convenience center. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Center Of Steering Wheel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Locations Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Locations > Page 11391 Lamp Control Module: Service and Repair Description Remove or Disconnect 1. Disable SIR system. 2. Left sound insulator. 3. Electrical connector. 4. Screws to dimmer module. Install or Connect 1. Screws to dimmer module. 2. Electrical connector. 3. Left sound insulator. 4. Enable SIR system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair Rear License Lamp Assembly REMOVE OR DISCONNECT 1. Bulb from socket by turning counterclockwise. INSTALL OR CONNECT 1. Bulb to socket by aligning tabs and turning clockwise. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Component Locations Marker Lamp: Component Locations LH Front Fender (RH Similar) LH Rear Fascia (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Component Locations > Page 11403 Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11406 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11407 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11408 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11409 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11410 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11411 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11412 Marker Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11413 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11414 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11415 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11416 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11417 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11418 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11419 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11420 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11421 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11422 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11423 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11424 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11433 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11434 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11435 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11436 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11437 Marker Lamp: Electrical Diagrams Tail/Rear Marker/License Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11438 Diagram(s) are part of the complete set of lighting diagrams located under "Lighting and Horns". Refer to this area if you need to find the accompanying diagrams or for testing information. See: Diagrams See: Testing and Inspection Turn/Hazard/Front Marker/Front Park Turn/Hazard/Front Marker/Front Park Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11439 Diagram(s) are part of the complete set of lighting diagrams located under "Lighting and Horns". Refer to this area if you need to find the accompanying diagrams or for testing information. See: Diagrams See: Testing and Inspection Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Front Side Marker Lamps Marker Lamp: Service and Repair Front Side Marker Lamps Side Marker Lamp REMOVE OR DISCONNECT 1. Headlamp assembly. 2. Socket from side marker lamp assembly. 3. lamp from front fender. INSTALL OR CONNECT 1. Lamp to front fender. 2. Socket to side marker lamp assembly. 3. Headlamp assembly. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Front Side Marker Lamps > Page 11442 Marker Lamp: Service and Repair Marker Lamp Replacement - Rear Side Rear Side Marker Lamp REMOVE OR DISCONNECT 1. Screw. 2. Lamp housing. 3. Bulb from socket. INSTALL OR CONNECT 1. Bulb to socket. 2. Lamp housing. 3. One screw. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair Turn Signal Lamp Turn Signal/Side Marker Lamp REMOVE OR DISCONNECT 1. Front inner wheel housing. 2. Socket by depressing locking tab and rotating socket counter-clockwise. 3. Bulb from socket. INSTALL OR CONNECT 1. Bulb to socket. 2. Socket in lamp housing and turn clockwise. 3. Front inner wheel housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 11451 Daytime Running Lamps Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 11456 Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Cut Off Relay > Page 11457 Rear Of Front Impact Bar Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 11458 Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations RH Upper I/P Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11462 Horn Relay: Service and Repair Description Remove or Disconnect 1. Convenience center. 2. Components from panel. Install or Connect 1. Install component into position and gently push forward until seated. 2. Convenience center. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Page 11466 Lamp Control Module: Service and Repair Description Remove or Disconnect 1. Disable SIR system. 2. Left sound insulator. 3. Electrical connector. 4. Screws to dimmer module. Install or Connect 1. Screws to dimmer module. 2. Electrical connector. 3. Left sound insulator. 4. Enable SIR system. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Back Up Lamp Switch LH Rear Of Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Back Up Lamp Switch > Page 11472 Backup Lamp Switch: Locations Wire Harness to TCC and Neutral Start and Backup Light SW LH Front Of Engine/Transaxle LH Engine/Transaxle Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 11473 Backup Lamp Switch: Service and Repair NOTICE: When removing or installing the backup light switch, DO NOT use a open end wrench. Use only a socket to avoid damage to the switch assembly. REMOVE OR DISCONNECT 1. Negative battery cable. 2. Backup lamp connector. 3. Backup light switch assembly. INSTALL OR CONNECT 1. Backup light switch assembly. - Use pipe sealant GM P/N 1052080 or equivalent. Tighten Backup light switch to 33 N.m (24 lb. ft.). 2. Backup light connector. 3. Negative battery cable. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations LH Lower I/P Below Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11477 Brake Switch: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11478 Brake Light Switch: Service and Repair Stop Light Switch REMOVE OR DISCONNECT 1. Driver side sound insulator. 2. Electrical connection. 3. Brake switch from retainer by grasping and pulling toward rear of vehicle. INSTALL OR CONNECT 1. Insert stop lamp switch into retainer until switch body seats on retainer. 2. Pull brake pedal upward against internal pedal stop. Switch will be moved in retainer providing proper adjustment. Proper switch adjustment is achieved when no clicks are heard when the pedal is pulled upward and the brake lights do not stay on without brake application. 3. Electrical connection. 4. Driver side sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch Connector RH Front Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch Connector > Page 11483 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Rear Of I/P Trim Plate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 11487 Folding Top Bypass Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 11488 Fog/Driving Lamp Switch: Description and Operation The fog lamp switch is located in the dimmer switch assembly. To turn on the fog lamps the ignition switch must be in the "RUN" position and the fog lamp switch must be in the "ON" position with the high beams off. When the fog lamps are turned on (head and park lamps off) the front and rear marker lamps, park lamps, tail lamps, license lamp and instrument panel lamps must also be on. When the high beam head lamps are selected, the fog lamps are turned off. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11492 Hazard Warning Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Headlamp Switch Lead Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Headlamp Switch Lead > Page 11497 LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11498 Headlamp Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Center Of Steering Wheel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11505 Turn Signal Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 11510 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 11511 Tail Lamp: Locations Top Of Rear Deck Lid LH Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11514 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11515 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11516 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11517 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11518 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11519 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11520 Tail Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11521 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11522 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11523 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11524 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11525 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11526 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11527 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11528 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11529 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11530 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11531 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11532 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11533 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11534 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11535 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11536 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11537 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11538 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11539 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11540 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11541 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11542 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11543 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11544 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Locations LH And RH Top Of Rear Wheel Wells Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions Trunk Lamp: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11550 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11551 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11552 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11553 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11554 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11555 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11556 Trunk Lamp: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11557 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11558 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11559 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11560 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11561 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11562 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11563 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11564 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11565 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11566 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11567 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11568 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11569 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11570 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11571 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11572 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11573 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11574 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11575 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11576 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11577 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11578 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11579 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11580 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations LH Lower I/P Near Steering Column Center Of Instrument Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 11585 Turn/Hazard Flasher Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 11586 Turn Signal Flasher: Service and Repair Description Remove or Disconnect 1. Left sound insulator. 2. Turn signal flasher from retainer. 3. Electrical connection. Install or Connect 1. Turn signal flasher to retainer. 2. Electrical connection. 3. Left sound insulator. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation When the Ignition Switch is in the "RUN" position, the hazard flashers off, and the turn signal lever is pulled down (left turn) the left turn indicator will flash to indicate the left turn signals are on. When the turn signal lever is lifted up (from the center position) the right turn indicator will flash to indicate the right turn signals are on. An audible "click" will also sound as an audible reminder that the turn signal is on. With the Ignition Switch in any position and the turn signal lever in any position and the hazard flasher switch pressed in, both the left turn and right turn indicators will flash simultaneously to indicate the hazard flashers are on. The turn signal indicators are turned on by the IPC when there are appropriate input signals. When the hazard flashers are on, the turn signals are disabled. Normal turn signal operation is restored when the hazard flashers are turned off. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair Turn Signal Lamp Turn Signal/Side Marker Lamp REMOVE OR DISCONNECT 1. Front inner wheel housing. 2. Socket by depressing locking tab and rotating socket counter-clockwise. 3. Bulb from socket. INSTALL OR CONNECT 1. Bulb to socket. 2. Socket in lamp housing and turn clockwise. 3. Front inner wheel housing. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11597 Turn Signal Switch: Diagrams Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Turn/Hazard - Headlamp Switch Assembly: C1 And C2 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations > Component Locations Headliner Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations > Component Locations > Page 11603 LH And RH Top Of Rear Wheel Wells Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Abbreviation A/C Air Conditioning CCM Central Control Module CKT Circuit CONN Connector EBCM Electronic Brake Control Module EBTCM Electronic Brake and Traction Control Module ECM Engine Control Module HARN Harness I/P Instrument Panel LH Left Hand PCM Powertrain Control Module RH Right Hand TERM Terminal Body Part Names Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11606 GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Electrostatic Discharge (ESD Sensitive Devices) All Electrostatic Discharge (ESD) sensitive components are Solid State and the following information applies to them. ESD Symbol Typical Schematic Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11607 The ESD symbol is used on schematics to indicate which components are ESD sensitive. When handling any electronic part, the service technician should follow the guidelines below to reduce any possible electrostatic charge build-up on the service technician's body and inadvertent discharge to the electronic part. If it is not known whether or not a component is ESD sensitive, assume it is susceptible. Handling Procedures 1. Always touch a known good ground before handling the part. This should be repeated while handling the pan and more frequently after sliding across a seat, sitting down from a standing position or walking a distance. 2. Avoid touching electrical terminals of the part, unless so instructed by a written diagnostic procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove a part from its protective package until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Measuring Procedures The circuits shown within the boxes are greatly simplified. Do not troubleshoot by measuring resistance at any terminal of these devices unless so instructed by a written diagnostic procedure. Due to the simplification of the schematics, resistance measurements could be misleading, or could lead to electrostatic discharge. Schematic Symbols Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11608 Fig.1-Symbols (Part 1 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11609 Fig.2-Symbols (Part 2 Of 3) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11610 Fig.3-Symbols (Part 3 Of 3) Vacuum Motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is applied, the shaft is pulled in. When no vacuum is applied, the shaft is pushed all the way out by a spring. Double Diaphragm Motors can be operated by vacuum in two directions. When there is no vacuum, the motor is in the center "at rest" position. Some Vacuum Motors such as the Servo Motor in the Cruise Control can position the actuating arm at any position between fully extended and fully retracted. The servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work like the two position motors; the only difference is in the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. Supplemental Inflatable Restraint (SIR) System SIR Symbol The Supplemental Inflatable Restraint (SIR) symbol is used on schematics to alert the technician to the following important caution. CAUTION: This vehicle is equipped with SIR. Refer to CAUTIONS in SIR under Air Bags and Seat Belts before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11611 Wire Color Code Identification Black: BLK Blue: BLU Brown: BRN Grey: GR Or GRY Green: GRN Natural: NAT Orange: ORN Pink: PNK Purple: PPL Red: RED Tan: TAN White: WHT Yellow: YEL Dark: DK (example: DK GRN same as Dark Green) Light: LT (example: LT BLU same as Light Blue) Wire Size Conversion Table Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11612 Heated Glass Element: Diagnostic Aids Additional Information NOTE: Turn OFF power to the test circuit before attempting in-circuit resistance measurements to prevent false readings or damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that work well for detecting intermittent shorts to ground can be performed by setting the meter to "ohms" then pressing the "PEAK MIN MAX" button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond. The J 39200 Instruction Manual is a good source of information and should be read thoroughly upon receipt of the meter as well as kept on hand for reference during new procedures. Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in this section. You should understand the basic theory of electricity and know the meaning of voltage, current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. The following four-step troubleshooting procedure is recommended: Step 1: Check the Problem Perform a System Check to determine a symptom. Don't waste time fixing part of the problem! Do not begin disassembly or testing until you have narrowed down the possible causes. Step 2: Read the Electrical Schematic Study the schematic. Read the Circuit Operation text if you do not understand how the circuit should work. Check circuits that share wiring with the problem circuit. (Shared circuits are shown on Power Distribution, Ground Distribution, Fuse Block Details and Light Switch Details.) Try to operate the shared circuits. If the shared circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty. Step 3: Find the fault and repair ^ Narrow down the possible causes. ^ Use the Troubleshooting Hints. ^ Make the necessary measurements or checks as given in the System Diagnosis. ^ Before replacing a component, check power, signal and ground wires at the component harness connector. If the checks and connections are OK, the most probable cause is component failure. Step 4: Test the Repair Repeat the System Check to verify that the fault has been corrected and that no other faults were induced during the repair. EXAMPLE: A customer brings in a vehicle and says that the HI beams do not work. Step 1: Perform a System Check on the Headlight Circuit You may discover that both LO beams operate. In HI, you may notice that the HI Beam Indicator comes ON, but neither HI beam operates. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11613 Typical Headlights Schematic Step 2: Read the Headlights Electrical Schematic This is the step that will save time and labor. Remember, it is essential to understand how a circuit should work, before trying to figure out why it doesn't. After you understand how the circuit should operate, read the schematic again, this time keeping in mind what you have learned by operating the circuit. Since both LO beams work, you know that the Headlight Switch, the YEL wire, the LO contacts of the Headlight Dimmer Switch, terminal "1E" of C100, the TAN wires and grounds G1O5 and G109 are all good. Furthermore, since you saw that the HI Beam Indicator came ON when the Headlight Dimmer Switch was moved to HI you know that the HI contacts of the Headlight Dimmer Switch and the LT GRN wire between the Headlight Dimmer Switch and C100 are good. At this point, you could test for voltage at the RH Headlamp with the Headlight Dimmer Switch in HI. However, it is extremely unlikely that the HI beam filaments have burned out in both headlamps, or that both headlamps connections are bad. The cause must be a bad connection at C100, or a break in the LT GRN wire between C100 and the RH Headlamp. You have quickly narrowed the possible causes down to one specific area, and have done absolutely no work on the vehicle itself. Step 3: Find the fault and repair it Using the Component Location List and the corresponding figure, you can quickly find C100 and the LT GRN wire, locate the exact trouble point and make the repair. Step 4: Check the repair by performing a System Check on the Headlights Circuit This, of course, means making sure that both HI beams, both LO beams and the HI Beam Indicator are all working. Now suppose that the symptoms were different. You may have operated the Headlamps and found that the LO beams were working, but neither the HI beams nor the HI Beam Indicator were working. Looking at the schematic, you might conclude that it is unlikely that both HI beam filaments and the HI Beam Indicator have all burned out at once. The cause is probably the Headlight Dimmer Switch or its connector. Checking Terminal Contacts Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11614 DESCRIPTION When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit, J 38125-A, J 38125-4 for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: Check for poor connection. Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation Of A Typical Metri-Pack 150/280/480/630 Series Female Terminal Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11615 Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit. PROCEDURE Follow the procedure below to check terminal contact. 1. Separate the connector halves. Refer to Terminal Repair Kit, J 38125-A, J 38125-4. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals, causing HI terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit, J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit, J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question (refer to Terminal Repair Kit, J 38125-A). If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a Digital Voltmeter (DVM) connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit. Detecting Electrical Intermittents PROCEDURE Use the following procedure to detect intermittent terminal contact or a broken wire with an intermittent connection inside the insulation. The J 39200 Digital Multimeter has the ability to monitor current, resistance, or voltage while recording the minimum (MIN) and maximum (MAX) values measured. The meter can also be set to display the average (AVG) value measured. When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector (or length of a circuit) which is suspected of having an intermittent connection but is currently operating normally. 1. Connect the J 39200 Digital Multimeter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the other. This will continuously monitor the terminal contacts or length of wire being checked. Refer Meter Connections for examples of the various methods for connecting the meter to the circuit. See: General Troubleshooting Procedures/Meter Connections 2. Set the meter for voltage. Since the "MIN MAX" mode does not use auto ranging, manually select the voltage range necessary before proceeding. 3. Press the "MIN MAX" button. The meter should read "100 ms RECORD" (100 millisecond record) and emit a 1/4 second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this point, you may wish to press the "PEAK MIN MAX" button, which will record any voltage variations that occur for at least 1 millisecond. 4. Try to simulate the condition that is potentially causing an intermittent connection, either by wiggling connections or wiring, test driving or performing other operations. If an open or resistance is created, a voltage will be present and the meter will emit a tone for as long as the open or resistance exists. Any change in voltage will cause the meter to emit a tone for no less than 1/4 second. (Listening for a tone while manipulating wiring is very helpful for narrowing down an intermittent connection.) Use the MIN and MAX values when the meter is out of sight or sound range, in noisy areas or for test driving when it may not be possible to monitor the meter. To check the MIN and MAX recorded voltages press "MIN MAX" once for MAX and twice for MIN. A variation between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or that resistance exists and should be repaired as necessary. IMPORTANT: The "100 ms RECORD" (100 millisecond record) mode is NOT the amount of time allowed to perform a specific procedure. It is the amount of time used to record each snapshot of information used for calculating "AVG" when in the "MIN MAX" mode. Intermittents and Poor Connections Most intermittents are caused by faulty electrical connections or wiring, although occasionally a sticking relay or solenoid can be a problem. Some items to check are: ^ Poor mating of connector halves, or terminals not fully seated in the connector body (backed out). ^ Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact. ^ Damaged connector body, exposing the terminals to moisture and dirt, as well as not maintaining proper terminal orientation with the component or mating connector. ^ Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal to check for proper tension. Refer to Checking Terminal Contact for the specific procedure. ^ The J 35616-A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the adapter will ensure that no damage to the terminal will occur, as well as giving an idea of whether contact tension is sufficient. If contact tension seems incorrect, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts ^ Poor terminal-to-wire connection. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over wire insulation rather than the wire itself, corrosion in the wire-to-terminal contact area, etc. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11616 ^ Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Wiring broken inside the insulation. This condition could cause a continuity check to show a good circuit, but if only 1 or 2 strands of a multi-strand type wire are intact, resistance could be far too HI. To avoid any of the above problems when making wiring or terminal repairs, always follow the instructions for wiring and terminal repair outlined under the Repair Procedures. See: Wire Repair Procedures/Typical Electrical Repair Procedures Meter Connections The previous diagnostic procedure was written to detect intermittents using the meter set to voltage. Whether using the current, voltage or resistance setting to detect intermittents, it is necessary to connect the meter to the circuit. Following are examples of the various methods of connecting the meter to the circuit to be checked: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while performing other operations or test driving. (Do not backprobe "Weather Pack(R)" type connectors.) ^ Disconnect the harness at both ends of the suspect circuit where it connects either to a component or to other harnesses. ^ Use Connector Test Adapter Kit J 35616-A to connect the meter to the circuit. ^ If the system being diagnosed has a specified Pinout or breakout box, it may be used to simplify connecting the meter to the circuit or for checking multiple circuits quickly. Aftermarket Accessories Always check for aftermarket accessories as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Some possible causes of vehicle problems related to aftermarket accessories include: 1. Power feeds connected to points other than the Battery. 2. Antenna location. 3. Transceiver wiring located too close to vehicle electronic modules or wiring. 4. Poor shielding or poor connectors on antenna feed line. Probing (Frontprobe & Backprobe) After probing, when reconnecting connectors or replacing terminals, always be sure to reinstall Connector Position Assurance (CPA) and Terminal Position Assurance (TPA). Frontprobe When frontprobing of connectors is required, always use a mating terminal adapter from Connector Test Adapter Kit (J 35616-A). The use of proper adapters will ensure that proper terminal contact integrity is maintained. (refer to Procedures in Checking Terminal Contact). Backprobe Only backprobe connector terminals when specifically called for in diagnostic procedures. Since backprobing can be a source of damage to connector terminals, extra care must be taken to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large a test probe. After backprobing any connector, always check for terminal damage. If terminal damage is suspected, check for proper terminal contact, refer to Checking Terminal Contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Testing For Voltage Voltage Check Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11617 1. Connect one lead of a test light to a known good ground. When using a Digital Voltmeter (DVM), be sure the voltmeter's negative lead is connected to ground. 2. Connect the other lead of the test light or voltmeter to a selected test point (connector or terminal). 3. If the test light illuminates, there is voltage present. When using a DVM, note the voltage reading. Testing For Continuity Continuity Check Through A Switch 1. Remove the fuse to the circuit involved. 2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit you wish to test. 3. Connect the other lead to the other end of the circuit. 4. If the self-powered test light glows, there is continuity. When using an ohmmeter, LO or no resistance means good continuity. Testing For Voltage Drop Voltage Drop Test This test checks for voltage being lost along a wire, or through a connection or switch. 1. Connect the positive lead of a Digital Voltmeter (DVM) to the end of the wire (or to one side of the connection or switch) which is closer to the Battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connection or switch). 3. Operate the circuit. 4. The DVM will show the difference in voltage between the two points. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11618 Testing For Short to Ground Testing For Short With Self Powered Test Light Or Ohmmeter WITH A TEST LIGHT OR DIGITAL VOLTMETER (DVM) 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or voltmeter across the fuse terminals (be sure that the fuse is powered). 3. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test light or DVM. 4. When the test light glows, or the DVM registers, there is a short to ground in the wiring near that point. Testing For Short With Test Light Or DVM WITH A SELF-POWERED TEST LIGHT OR OHMMETER. 1. Remove the blown fuse and disconnect the Battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the Fuse Block, wiggle the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the self-powered test light or ohmmeter. 5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in the wiring near that point. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11619 FUSES POWERING SEVERAL LOADS 1. Find the schematic under "Fuse Block Details," for the fuse that has blown. 2. Open the first connector or switch leading from the fuse to each load. 3. Replace the fuse. ^ If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test light or meter as described. ^ If fuse does not blow, refer to next step. 4. Close each connector or switch until the fuse blows in order to find which circuit has the short. Connect test lamp or meter at the connector to the suspect circuit (disconnected) rather than at the fuse terminals. Test Light/Digital Voltmeter Use a test light to check for voltage. A Test Light (J 34l42-B) is made up of a 12 volt light bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. When the bulb goes ON, there is voltage at the point being tested. A Digital Voltmeter (DVM) can be used instead of a test light. While a test light shows whether or not voltage is present, a DVM indicates how much voltage is present. An increasing number of circuits include solid state control modules. One example is the Engine Control Module (ECM). Voltages in these circuits should be tested only with a 10-megohm or higher impedance DVM or multimeter (J 39200). Unless directed to within the diagnostics, NEVER use a test light on circuits that contain solid state components, since damage to these components may result. When testing for voltage or continuity at the connection, it is not necessary to separate the two halves of the connector. Unless testing a Weather Pack(R) connector, always probe the connector from the back. Always check both sides of the connector. An accumulation of dirt and corrosion between contact surfaces is sometimes a cause of electrical problems. Refer to Procedures in checking terminal contact. See: General Troubleshooting Procedures/Checking Terminal Contacts Connector Test Adapters Connector Test Adapter Kit (J 35616-A) is available for making tests and measurements at separated connectors. This kit contains an assortment of probes which mate with many of the types of terminals you will see. Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements. Self-Powered Test Light A self-powered test light (J 21008-A) can be used to check for continuity. This tool is made up of a light bulb, Battery and two leads. If the leads are touched together, the bulb will go ON. A self-powered test light is used only on an unpowered circuit. First remove the fuse which feeds the circuit you're working on. Select two specific points along the circuit through which there should be continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light circuit will be completed and the bulb will go ON. NEVER use a self-powered test light on circuits that contain solid state components, since damage to these components may result. Ohmmeter An ohmmeter can be used instead of a self-powered test light. The ohmmeter shows how much resistance there is between two points along a circuit. LO resistance means good continuity. Circuits which include any solid state control modules, such as the Engine Control Module (ECM), should be tested only with a 10-megohm or higher impedance digital multimeter (J 39200). When measuring resistance with a Digital Voltmeter (DVM), the vehicle Battery should be disconnected. This will prevent incorrect readings. DVMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the solid state component is affecting the measurement. Fused Jumper Wire A fused jumper (J 36169) is available with small clamp connectors providing adaptation to most connectors without damage. This fused jumper wire is supplied with a 20 amp fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. NOTE: A fused jumper may not protect solid state components from being damaged. Short Finder Short Finders (J 8681-A) are available to locate hidden shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the location of the short through body trim or sheet metal. Fuse Tester Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11620 A simple tester (J 34764) can detect a blown fuse. To check a fuse, the tester is applied directly to the fuse in the Fuse Block. Two probes contact the fuse, either into the slots of a flat fuse or to the metal ends of a glass fuse. With power ON, a red Light Emitting Diode (LED) in the tester lights if the fuse is open. The handle of the tester is a tool for removing either type of fuse. Special Tools Circuit Breakers A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. There are two basic types of circuit breakers used in GM vehicles: cycling and non-cycling. Cycling Circuit Breaker The cycling breaker will open due to heat generated when excessive current passes through it for a period of time. Once the circuit breaker cools, Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11621 it will close again after a few seconds. If the cause of the HI current is still present it will open again. It will continue to cycle open and closed until the condition causing the HI current is removed. Non-Cycling Circuit Breaker There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker. This wire provides enough heat to keep the bimetallic element open until the current source is removed. The other type is solid state, called out in this section as Electronic Circuit Breaker (ECB). This device has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current passes through it. The excessive current heats the ECB. As it heats, its resistance increases, therefore having a Positive Temperature Coefficient. Eventually the resistance gets so HI that the circuit is effectively open. The ECB will not reset until the circuit is opened, removing voltage from its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two. Fuses Fuse Devices The most common method of automotive wiring circuit protection is the fuse. A fuse is a device that, by the melting of its element, opens an electrical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse must be replaced each time a circuit is overloaded or after a malfunction is repaired. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11622 Fuse Rating And Color Fuses are color coded. The standardized color identification and ratings are shown. For service replacement, non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse for a break in the element. If the element is broken or melted, replace the fuse with one of equal current rating. There are additional specific circuits with in-line fuses. These fuses are located within the individual wiring harness and will appear to be an open circuit if blown. Autofuse The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the Fuse Block and the system components. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11623 Maxifuse The Maxifuse was designed to replace the fusible link and Pacific Fuse elements. The Maxifuse is designed to protect cables, normally between the battery and fuse block, from both direct short circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse element, the Maxifuse performs much more like an Autofuse, although the average opening time is slightly longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance of nuisance blows. Minifuse The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the Autofuse, the Minifuse is usually used to protect the wiring assembly between a fuse block and system components. Since the Minifuse is a smaller device, it allows for more system specific fusing to be accomplished within the same amount of space as Autofuses. Pacific Fuse Element/Maxifuse The Pacific Fuse Element and Maxifuse were developed to be a replacement for the fusible link. Like a fusible link, the fuses are designed to protect wiring from a direct short to ground. These elements are easier to service and inspect than a fusible link and will eventually replace fusible links in all future vehicle applications. Fusible Links Good And Damaged Fusible Links In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like fuses, fusible links are "one-time" protection devices that will melt and create an open circuit. Not all fusible link open Circuits can be detected by observation. Always inspect that there is battery voltage past the fusible link to verify continuity. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11624 Wire Size Conversion Table Fusible links are used instead of a fuse in wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a 10 gage wire use a 14 gage link or for metric, to protect a 5 mm Sq. wire use a 2 mm Sq. link, refer to Wire Size Conversion Table. Links are marked on the insulation with wire-gage size because the heavy insulation makes the link appear to be a heavier gage than it actually is. The same wire size fusible link must be used when replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R), Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible links. Determining characteristics of the types of fusible links are: - Hypalon(R) (limited use): only available in 0.35 mm Sq. or smaller and its insulation is one color all the way through. - SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of insulation. - Expanded Duty: available in all sizes, has an insulation that is one color all the way through and has three dots following the writing on the insulation. Service fusible links are available in many lengths. Service fusible links are available in many lengths. Choose the shortest length that is suitable. If the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx. 6-9 in.) long. NEVER make a fusible link longer than 225 mm (approx. 9 in.). CAUTION: Fusible links cut longer than 225 mm (approx. 9 in.) will not provide sufficient overload protection. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11625 Single Wire Feed Fusible Link To replace a damaged fusible link, cut it off beyond the splice. Replace with a repair link. When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely in two places. For more details on splicing procedures, refer to "Typical Electrical Repair Procedures." Use crimp and seal splices whenever possible. See: Wire Repair Procedures/Typical Electrical Repair Procedures Double Wire Feed Fusible Link To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the splice. Use two repair links, one spliced to each harness wire. General Information The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions. An overload is defined as a current requirement that is higher than normal. This overload could be caused by a short circuit or system malfunction. The short circuit could be the result of a pinched or cut wire or an internal device short circuit, such as an electronic module failure. The circuit protection device is only applied to protect the wiring assembly, and not the electrical load at the end of the assembly. For example, if an electronic component short circuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly. However, it will not necessarily prevent damage to the component. There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link. Diode Replacement Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode, use the following procedure: Step 1: Open the Harness If the diode is taped to the harness, remove all of the tape. Step 2: Remove inoperative Diode Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. Step 3: Strip the Insulation Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11626 Diode Identification Step 4: Install New Diode Check current flow direction of the new diode, being sure to install the diode with correct bias. Refer the image for replacement diode symbols and current flow explanations. Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a beat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturer's instructions for the soldering equipment you are using. Step 5: Install Terminal(s) Install terminal(s) into the connector body if previously removed in Step 2. Step 6: Tape Diode to Harness Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points. Acceptable Diode Replacements In the event 1 amp, 50 PIV (Peak Inverse Rating) diodes are unavailable, a universal diode with a 1 amp, 400 PIV rating can be used for the following applications: ^ A/C Compressor Clutch ^ ABS/4WAL (the ABS Diode on the Delco Moraine is hidden inside of an electrical connector under the carpet at the RH panel) ^ Wiper ^ Charging System (hidden in wire harness) ^ Parking Brake (vehicle with ABS) ^ Relays ^ Solenoids ^ Diesel Glow Plug Circuit General Information OPEN CIRCUIT An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is open, active components do not energize. SHORT CIRCUIT A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to blow or a circuit breaker to open. Heated Oxygen Sensor (O2S) Repair Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11627 If the Heated Oxygen Sensor pigtail wiring, connector or terminal is damaged, the entire Oxygen Sensor Assembly must be replaced. Do not attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have provided to it a clean air reference. This clean air reference is obtained by way of the Oxygen Sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degraded Oxygen Sensor performance. The following guidelines should be used when servicing the Heated Oxygen Sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor or vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the Oxygen Sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The Engine Harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit J 38125-A. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. General Information ^ The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general groups: Push-to-Seat, Pull-to-Seat and Weather Pack(R). ^ Use the proper Pick(s) or Tool(s) that apply to the terminal. ^ The Terminal Repair Kit (J 38125-A) contains further information. Push-to-Seat and Pull-to-Seat Connectors Typical Push-to-seat Connector And Terminal Typical Pull-to-seat Connector And Terminal Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors. The steps are illustrated with typical connectors. Your connector may differ, but the repair steps are similar. Some connectors do not require all the steps shown. Skip those that don't apply. Step 1: Remove any Connector Position Assurance (CPA) Locks . CPAs are designed to retain connectors when mated. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11628 Step 2: Remove any Terminal Position Assurance (TPA) Locks. TPAs are designed to keep the terminal from backing out of the connector. NOTE: The TPA must be removed prior to terminal removal and must be replaced when the terminal is repaired and reseated. Step 3: Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to the connector. Step 4: Separate the connector halves and back out seals. Step 5: Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 6: Locate the terminal lock tang in the connector canal. Step 7: Insert the proper size pick (refer to Terminal Repair kit J 38125-A) straight into the connector canal at the mating end of the connector. Step 8: Depress the locking tang to unseat the terminal. ^ Push-to-Seat - Gently pull on the lead to remove the terminal through the back of the connector. ^ Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 9: Inspect terminal and connector for damage. Repair as necessary (refer to Terminal Repairs). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 10: Reform lock tang and reseat terminal in connector body. Apply grease if connector was originally equipped with grease. Step 11: Install any CPAs or TPAs, close any secondary locks and join connector halves. Weather Pack(R) Connectors Typical Weather Pack(R) Connector And Terminal Follow the steps below to repair Weather Pack(R) connectors. Step 1: Separate the connector halves. Step 2: Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector. Step 3: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11629 Grasp the lead and push the terminal to the forward most position. Hold the lead at this position. Step 4: Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder. Step 5: Gently pull on the lead to remove the terminal through the back of the connector. NOTE: NEVER use force to remove a terminal from a connector. Step 6: Inspect the terminal and connector for damage. Repair as necessary (refer to Terminal Repair). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Terminal Repairs Step 7: Re-form the lock tang and reseat terminal in connector body. Step 8: Close secondary locks and join connector halves. Repairing Short Circuits Caused By Damaged Wire ^ Locate the damaged wire. ^ Find and correct the cause of the wire insulation damage. ^ For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the Splicing Instructions for copper or shielded cable for the correct splicing procedure). See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Splice Clips See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Copper Wire Using Crimp and Seal Splice Sleeves See: Wire Repair Procedures/Typical Electrical Repair Procedures/Splicing Twisted/Shielded Cable Splicing Copper Wire Using Crimp and Seal Splice Sleeves Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial and may only be used to form a one-to-one splice. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage. Wire Size Conversion Table Step 3: Strip the Insulation If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11630 To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section. Crimp And Seal Splice Sleeve Chart Step 4: Select and Position the Splice Sleeve Select the proper splice sleeve according to wire size. The splice sleeves and tool tests are color coded (refer to Chart). Hand Crimp Tool Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. Seal Splice Sequence The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest. Step 5: Insert Wires into Splice Sleeve and Crimp Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice. Step 6: Shrink the Insulation Around the Splice Using the Ultratorch J 38125-5 (follow instructions that accompany Ultratorch), apply heat where the barrel is crimped. Gradually move the heat Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11631 barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved. Splicing Copper Wire Using Splice Clips Splice clips are included in the J 38125-A Terminal Repair Kit. The splice clip is a general purpose wire repair device. It may not be acceptable for applications having special requirements such as moisture sealing. Step 1: Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). If the harness has a black plastic conduit, simply pull out the desired wire. Step 2: Cut the Wire Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches or connectors. Wire Size Conversion Table Step 3: Strip the Insulation When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metric units. The table shows the commercial AWG wire sizes that can be used to replace each metric wire size. Each AWG size is either equal to or larger than the equivalent metric size. To find the correct wire size either find the wire on the schematic page and convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire size, start with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Be careful to avoid nicking or cutting any of the wires. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11632 Entering The Splice Clip Step 4: Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the stripped wire ends and hold them between your thumb and forefinger as shown. Then, center the splice clip under the stripped wires and hold it in place. ^ Open the crimping tool to its full width and rest one handle on a firm flat surface. ^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. Crimping The Splice Clip ^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes. ^ Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. - No strands of wire are cut loose. - No insulation is caught under the clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11633 Completing The Crimp Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires. Applying The Solder Step 5: Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instruction for the solder equipment you are using. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11634 Proper First Taping Step 6: Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness. Proper Second Taping If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape. Splicing Twisted/Shielded Cable Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11635 Twisted/shielded Cable Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For example, two-conductor cable of this construction is used between the Engine Control Module (ECM) and the distributor. Step 1: Remove Outer Jacket Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar tape. Step 2: Unwrap the Tape Unwrap the aluminium/mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors after the splices have been made. The Untwisted Conductors Step 3: Prepare the Splice Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper wire presented earlier. Remember to stagger splices to avoid shorts. Step 4: Re-assemble the Cable After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid wrapping the drain wire in the tape. The Re-assembled Cable Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11636 Proper Taping Step 5: Tape the Cable Tape over the entire cable using a winding motion. This tape will replace the section of the jacket you removed to make the repair. Terminal Repairs Terminal Repair The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather Pack(R) terminals. Some terminals do not require all steps shown. Skip those that don't apply. The Terminal Repair Kit (J 38125-A) contains further information. Step 1: Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for Weather Pack(R) terminals. Step 2: Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal (Weather Pack(R) terminals only). Step 3: Remove insulation. Step 4: Align seal with end of cable insulation (Weather Pack(R) terminals only). Step 5: Position strip (and seal for Weather Pack(R)) in terminal. Step 6: Hand crimp core wings. Step 7: Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal and cable (Weather Pack(R)). Step 8: Solder all hand crimped terminals. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11637 Heated Glass Element: Connector Views Heater - A/C And Rear Defogger Control Assembly: C2 Heater - A/C And Rear Defogger Control Assembly: C1 Heater - A/C And Rear Defogger Control Assembly: C3 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11638 Heater - A/C And Rear Defogger Control Assembly: C1 Heater - A/C And Rear Defogger Control Assembly: C1 Heater - A/C And Rear Defogger Control Assembly: C2 Heater - A/C And Rear Defogger Control Assembly: C3 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11639 Rear Defogger Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 11640 Heated Glass Element: Description and Operation With the Ignition Switch in "RUN," voltage is applied to the Rear Defogger Control Switch. When the Rear Defogger Control Switch is pressed, voltage is applied to the solid state Timing Circuit, providing voltage to the "ON" Indicator and the rear Defogger. The rear window becomes warm to remove the condensation from the surface of the window. The contact in the Timing Circuit stays closed until the Rear Defogger Control Switch is pressed again, the timer cycle is complete, or the Ignition Switch is turned to "OFF." The first time the Rear Defogger Control Switch is pressed, the Timing Circuit allows the Rear Defogger to operate for approximately 10 minutes. Each time after that when the Rear Defogger Control Switch is pressed, the Timing Circuit operates for approximately 5 minutes. The Timing Circuit resets to 10 minutes when the Ignition Switch is turned "OFF." Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures Heated Glass Element: Diagnostic Trouble Code Tests and Associated Procedures Circuit Operation With the Ignition Switch in "RUN," voltage is applied to the Rear Defogger Control Switch. When the Rear Defogger Control Switch is pressed, voltage is applied to the solid state Timing Circuit, providing voltage to the "ON" Indicator and the rear Defogger. The rear window becomes warm to remove the condensation from the surface of the window. The contact in the Timing Circuit stays closed until the Rear Defogger Control Switch is pressed again, the timer cycle is complete, or the Ignition Switch is turned to "OFF." The first time the Rear Defogger Control Switch is pressed, the Timing Circuit allows the Rear Defogger to operate for approximately 10 minutes. Each time after that when the Rear Defogger Control Switch is pressed, the Timing Circuit operates for approximately 5 minutes. The Timing Circuit resets to 10 minutes when the Ignition Switch is turned "OFF." System Check System Diagnosis - Rear Window Defogger & Heated Mirrors (SSE & SSEI Models) ^ Perform the "System Check" and refer to the "Symptom Table" for the appropriate diagnostic procedures. Troubleshooting Hints PERFORM BEFORE BEGINNING SYSTEM DIAGNOSIS: 1. Check RR Defog Fuse and the HVAC Fuse. 2. Refer to repair Procedures If one or more of the grid lines do not heat. 3. If the Panel Light is inoperable with the Headlamp Switch in "PARK" or "HEAD," check bulb and wiring to bulb (CKT 8 - Power, CKT 150. Ground). ^ Refer to Wiper and Washer Systems for Wiper/Washer Switch access. See: Wiper and Washer Systems ^ Check for a broken (or partially broken) wire inside of the insulation which could cause system failure but prove "GOOD" in a continuity/voltage check (refer to "General Troubleshooting Procedures,"). See: Diagrams/Diagnostic Aids ^ Check for proper installation of aftermarket electronic equipment which may affect the integrity of other systems (refer to "General Troubleshooting Procedures,"). ^ Refer to "System Diagnosis". Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Diagnostic Trouble Code Tests and Associated Procedures > Page 11643 Heated Glass Element: Symptom Related Diagnostic Procedures Symptom Table Chart #1 Rear Defogger Does Not Operate Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection > Page 11648 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations LH Center Console LH Center Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Component Locations > Page 11654 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 11655 Power Window Switch: Diagrams Master Window Switch: 4 Door (C1 And C2) Master Window Switch: 4 Door (C1 And C2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 11656 Rear Window And Door Lock Switches Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Front LH Front Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Front > Page 11662 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch Power Window Motor: Service and Repair Power Door Lock Switch POWER DOOR LOCK SWITCH REMOVE OR DISCONNECT 1. Pry power door lock switch using a flat blade screwdriver. 2. Power door lock switch wire harness. 3. Power door lock switch. INSTALL OR CONNECT 1. Power door lock switch wire harness. 2. Power door lock switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11665 Power Window Motor: Service and Repair Power Window Switch POWER WINDOW SWITCH REMOVE OR DISCONNECT 1. Pry power window switch using a flat blade screwdriver. 2. Power window switch wire harness. 3. Power window switch. INSTALL OR CONNECT 1. Power window switch wire harness. 2. Power window switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11666 Power Window Motor: Service and Repair Door Window Regulator Handle DOOR WINDOW REGULATOR HANDLE Door Window Regulator Handle TOOLS REQUIRED ^ J 9886-01 Regulator Handle Clip Remover REMOVE OR DISCONNECT 1. Door window regulator handle in the upward position. 2. Insert tool J 9886-01 or equivalent between door window regulator handle and door trim panel and push downward. 3. Door window regulator handle. 4. Door window regulator handle bearing plate. INSTALL OR CONNECT 1. Retaining clip to door window regulator handle. 2. Door window regulator handle bearing plate. 3. Door window in the closed position. 4. Push door window regulator handle to secure retaining clip. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11667 Power Window Motor: Service and Repair Front Door Upper Trim Finish Panel FRONT DOOR UPPER TRIM FINISH PANEL Front Door Upper Trim Finish Panel REMOVE OR DISCONNECT 1. Front door upper trim finish panel screw. 2. Power mirror switch. 3. Front door upper trim finish panel. INSTALL OR CONNECT 1. Power mirror switch to front door upper trim finish panel. 2. Front door upper trim finish panel. 3. Front door upper trim finish panel screw. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11668 Power Window Motor: Service and Repair Power Door Lock Switch POWER DOOR LOCK SWITCH REMOVE OR DISCONNECT 1. Pry power door lock switch using a flat blade screwdriver. 2. Power door lock switch wire harness. 3. Power door lock switch. INSTALL OR CONNECT 1. Power door lock switch wire harness. 2. Power door lock switch. Power Window Switch POWER WINDOW SWITCH REMOVE OR DISCONNECT 1. Pry power window switch using a flat blade screwdriver. 2. Power window switch wire harness. 3. Power window switch. INSTALL OR CONNECT 1. Power window switch wire harness. 2. Power window switch. Door Window Regulator Handle DOOR WINDOW REGULATOR HANDLE Door Window Regulator Handle TOOLS REQUIRED ^ J 9886-01 Regulator Handle Clip Remover REMOVE OR DISCONNECT 1. Door window regulator handle in the upward position. 2. Insert tool J 9886-01 or equivalent between door window regulator handle and door trim panel and push downward. 3. Door window regulator handle. 4. Door window regulator handle bearing plate. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11669 INSTALL OR CONNECT 1. Retaining clip to door window regulator handle. 2. Door window regulator handle bearing plate. 3. Door window in the closed position. 4. Push door window regulator handle to secure retaining clip. Front Door Upper Trim Finish Panel FRONT DOOR UPPER TRIM FINISH PANEL Front Door Upper Trim Finish Panel REMOVE OR DISCONNECT 1. Front door upper trim finish panel screw. 2. Power mirror switch. 3. Front door upper trim finish panel. INSTALL OR CONNECT 1. Power mirror switch to front door upper trim finish panel. 2. Front door upper trim finish panel. 3. Front door upper trim finish panel screw. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.) Door Trim Panel DOOR TRIM PANEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11670 Front Door Trim Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11671 Rear Door Trim Panel TOOLS REQUIRED: ^ J 24595-C Door Trim Pad Remover REMOVE OR DISCONNECT 1. Power door lock switch. 2. Power window switch. 3. Door window regulator handle. 4. Front door upper trim finish panel. 5. Door trim panel lower screws. 6. Door arm rest screws. 7. (Sedan front and coupe only) Door trim clips at sealing strip. 8. Door trim panel fasteners from door inner panel using tool J 24595-C. 9. Door trim panel. INSTALL OR CONNECT 1. Push door trim panel to engage fasteners. 2. (Sedan front and coupe only) Push door trim panel outward and downward at sealing strip to engage clips to door inner. 3. Door arm rest screws. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11672 TIGHTEN ^ Screw to 1.5 Nm (13.3 lb. in.). 4. Door trim panel lower screws. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.). 5. Front door upper trim finish panel. 6. Door window regulator handle. 7. Power window switch. 8. Power door lock switch. Door Armrest Hanger Plate DOOR ARMREST HANGER PLATE Front Door Armrest Hanger Plate Front Door Armrest Hanger Plate REMOVE OR DISCONNECT Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11673 1. Door trim panel. 2. Door armrest hanger plate rivets. 3. Door armrest hanger plate. INSTALL OR CONNECT 1. Door armrest hanger plate. 2. Door armrest hanger plate rivets. 3. Door trim panel. Door Water Deflector DOOR WATER DEFLECTOR REMOVE OR DISCONNECT 1. Door trim panel. 2. Door armrest hanger plate. 3. Pull door water deflector from door inner panel. INSTALL OR CONNECT 1. Sealer to original sealing areas on water deflector. NOTICE: Proper sealing is necessary to prevent water entry into door and possible damage to inner door components. If necessary, replace with new deflector. 2. Water deflector. 3. Door armrest hanger plate. 4. Door trim panel. Window Regulator Assembly DOOR REGULATOR ASSEMBLY Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11674 Front Door Window Regulator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11675 Rear Door Window Regulator REMOVE OR DISCONNECT 1. Door trim panel. 2. Enough door water deflector to access door window regulator. 3. Door window assembly. 4. (Front Door Only) Door regulator bolts. 5. Door regulator rivets. 6. Door regulator. INSTALL OR CONNECT 1. Door regulator. 2. Door regulator rivets. 3. (Front Door Only) Door regulator bolts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11676 TIGHTEN ^ Bolt to 10 Nm (89 lb. in.). 4. Door regulator nuts. TIGHTEN ^ Nut to 10 Nm (89 lb. in.). 5. Door window assembly. 6. Door water deflector. 7. Door trim panel. Door Window Assembly DOOR WINDOW ASSEMBLY Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11677 Front Door Window Assembly Rear Door Window Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Power Door Lock Switch > Page 11678 Door Window Assembly Sash REMOVE OR DISCONNECT 1. Door window assembly to the down position to align with access holes. 2. Door trim panel. 3. Enough door water deflector to access door window assembly nuts. 4. Door window assembly nuts. 5. Bolts and rear door energy absorber. 6. Lift rear of door window assembly, then front of door window assembly. 7. Door window assembly from outside of door. 8. Door window assembly sash rivet. 9. Door window assembly sash. INSTALL OR CONNECT 1. Door window assembly sash. 2. Door window assembly sash rivet. 3. Door window assembly from outside of door. 4. Door window assembly by inserting front of door window assembly, then rear of door window assembly. 5. Door window assembly nuts. TIGHTEN ^ Nut to 10 Nm (89 lb. in.). 6. Rear door energy absorber and bolts. 7. Door water deflector. 8. Door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations Power Window Switch: Component Locations LH Center Console LH Center Console Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Component Locations > Page 11683 LH Rear Door (RH Similar) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 11684 Power Window Switch: Diagrams Master Window Switch: 4 Door (C1 And C2) Master Window Switch: 4 Door (C1 And C2) Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 11685 Rear Window And Door Lock Switches Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Back Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 11699 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 11700 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate Window Regulator: Service and Repair Door Armrest Hanger Plate DOOR ARMREST HANGER PLATE Front Door Armrest Hanger Plate Front Door Armrest Hanger Plate REMOVE OR DISCONNECT 1. Door trim panel. 2. Door armrest hanger plate rivets. 3. Door armrest hanger plate. INSTALL OR CONNECT 1. Door armrest hanger plate. 2. Door armrest hanger plate rivets. 3. Door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11709 Window Regulator: Service and Repair Door Trim Panel DOOR TRIM PANEL Front Door Trim Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11710 Rear Door Trim Panel TOOLS REQUIRED: ^ J 24595-C Door Trim Pad Remover REMOVE OR DISCONNECT 1. Power door lock switch. 2. Power window switch. 3. Door window regulator handle. 4. Front door upper trim finish panel. 5. Door trim panel lower screws. 6. Door arm rest screws. 7. (Sedan front and coupe only) Door trim clips at sealing strip. 8. Door trim panel fasteners from door inner panel using tool J 24595-C. 9. Door trim panel. INSTALL OR CONNECT 1. Push door trim panel to engage fasteners. 2. (Sedan front and coupe only) Push door trim panel outward and downward at sealing strip to engage clips to door inner. 3. Door arm rest screws. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11711 TIGHTEN ^ Screw to 1.5 Nm (13.3 lb. in.). 4. Door trim panel lower screws. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.). 5. Front door upper trim finish panel. 6. Door window regulator handle. 7. Power window switch. 8. Power door lock switch. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11712 Window Regulator: Service and Repair Door Water Deflector DOOR WATER DEFLECTOR REMOVE OR DISCONNECT 1. Door trim panel. 2. Door armrest hanger plate. 3. Pull door water deflector from door inner panel. INSTALL OR CONNECT 1. Sealer to original sealing areas on water deflector. NOTICE: Proper sealing is necessary to prevent water entry into door and possible damage to inner door components. If necessary, replace with new deflector. 2. Water deflector. 3. Door armrest hanger plate. 4. Door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11713 Window Regulator: Service and Repair Door Window Assembly DOOR WINDOW ASSEMBLY Front Door Window Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11714 Rear Door Window Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11715 Door Window Assembly Sash REMOVE OR DISCONNECT 1. Door window assembly to the down position to align with access holes. 2. Door trim panel. 3. Enough door water deflector to access door window assembly nuts. 4. Door window assembly nuts. 5. Bolts and rear door energy absorber. 6. Lift rear of door window assembly, then front of door window assembly. 7. Door window assembly from outside of door. 8. Door window assembly sash rivet. 9. Door window assembly sash. INSTALL OR CONNECT 1. Door window assembly sash. 2. Door window assembly sash rivet. 3. Door window assembly from outside of door. 4. Door window assembly by inserting front of door window assembly, then rear of door window assembly. 5. Door window assembly nuts. TIGHTEN ^ Nut to 10 Nm (89 lb. in.). 6. Rear door energy absorber and bolts. 7. Door water deflector. 8. Door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11716 Window Regulator: Service and Repair Door Armrest Hanger Plate DOOR ARMREST HANGER PLATE Front Door Armrest Hanger Plate Front Door Armrest Hanger Plate REMOVE OR DISCONNECT 1. Door trim panel. 2. Door armrest hanger plate rivets. 3. Door armrest hanger plate. INSTALL OR CONNECT 1. Door armrest hanger plate. 2. Door armrest hanger plate rivets. 3. Door trim panel. Door Trim Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11717 DOOR TRIM PANEL Front Door Trim Panel Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11718 Rear Door Trim Panel TOOLS REQUIRED: ^ J 24595-C Door Trim Pad Remover REMOVE OR DISCONNECT 1. Power door lock switch. 2. Power window switch. 3. Door window regulator handle. 4. Front door upper trim finish panel. 5. Door trim panel lower screws. 6. Door arm rest screws. 7. (Sedan front and coupe only) Door trim clips at sealing strip. 8. Door trim panel fasteners from door inner panel using tool J 24595-C. 9. Door trim panel. INSTALL OR CONNECT 1. Push door trim panel to engage fasteners. 2. (Sedan front and coupe only) Push door trim panel outward and downward at sealing strip to engage clips to door inner. 3. Door arm rest screws. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11719 TIGHTEN ^ Screw to 1.5 Nm (13.3 lb. in.). 4. Door trim panel lower screws. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.). 5. Front door upper trim finish panel. 6. Door window regulator handle. 7. Power window switch. 8. Power door lock switch. Door Water Deflector DOOR WATER DEFLECTOR REMOVE OR DISCONNECT 1. Door trim panel. 2. Door armrest hanger plate. 3. Pull door water deflector from door inner panel. INSTALL OR CONNECT 1. Sealer to original sealing areas on water deflector. NOTICE: Proper sealing is necessary to prevent water entry into door and possible damage to inner door components. If necessary, replace with new deflector. 2. Water deflector. 3. Door armrest hanger plate. 4. Door trim panel. Door Window Assembly DOOR WINDOW ASSEMBLY Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11720 Front Door Window Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11721 Rear Door Window Assembly Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11722 Door Window Assembly Sash REMOVE OR DISCONNECT 1. Door window assembly to the down position to align with access holes. 2. Door trim panel. 3. Enough door water deflector to access door window assembly nuts. 4. Door window assembly nuts. 5. Bolts and rear door energy absorber. 6. Lift rear of door window assembly, then front of door window assembly. 7. Door window assembly from outside of door. 8. Door window assembly sash rivet. 9. Door window assembly sash. INSTALL OR CONNECT 1. Door window assembly sash. 2. Door window assembly sash rivet. 3. Door window assembly from outside of door. 4. Door window assembly by inserting front of door window assembly, then rear of door window assembly. 5. Door window assembly nuts. TIGHTEN ^ Nut to 10 Nm (89 lb. in.). 6. Rear door energy absorber and bolts. 7. Door water deflector. 8. Door trim panel. Door Window Regulator Handle DOOR WINDOW REGULATOR HANDLE Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11723 Door Window Regulator Handle TOOLS REQUIRED ^ J 9886-01 Regulator Handle Clip Remover REMOVE OR DISCONNECT 1. Door window regulator handle in the upward position. 2. Insert tool J 9886-01 or equivalent between door window regulator handle and door trim panel and push downward. 3. Door window regulator handle. 4. Door window regulator handle bearing plate. INSTALL OR CONNECT 1. Retaining clip to door window regulator handle. 2. Door window regulator handle bearing plate. 3. Door window in the closed position. 4. Push door window regulator handle to secure retaining clip. Front Door Upper Trim Finish Panel FRONT DOOR UPPER TRIM FINISH PANEL Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11724 Front Door Upper Trim Finish Panel REMOVE OR DISCONNECT 1. Front door upper trim finish panel screw. 2. Power mirror switch. 3. Front door upper trim finish panel. INSTALL OR CONNECT 1. Power mirror switch to front door upper trim finish panel. 2. Front door upper trim finish panel. 3. Front door upper trim finish panel screw. TIGHTEN ^ Screw to 1.3 Nm (11.5 lb. in.) Power Door Lock Switch POWER DOOR LOCK SWITCH REMOVE OR DISCONNECT 1. Pry power door lock switch using a flat blade screwdriver. 2. Power door lock switch wire harness. 3. Power door lock switch. INSTALL OR CONNECT 1. Power door lock switch wire harness. 2. Power door lock switch. Power Window Switch POWER WINDOW SWITCH REMOVE OR DISCONNECT 1. Pry power window switch using a flat blade screwdriver. 2. Power window switch wire harness. 3. Power window switch. INSTALL OR CONNECT 1. Power window switch wire harness. 2. Power window switch. Window Regulator Assembly DOOR REGULATOR ASSEMBLY Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11725 Front Door Window Regulator Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11726 Rear Door Window Regulator REMOVE OR DISCONNECT 1. Door trim panel. 2. Enough door water deflector to access door window regulator. 3. Door window assembly. 4. (Front Door Only) Door regulator bolts. 5. Door regulator rivets. 6. Door regulator. INSTALL OR CONNECT 1. Door regulator. 2. Door regulator rivets. 3. (Front Door Only) Door regulator bolts. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Door Armrest Hanger Plate > Page 11727 TIGHTEN ^ Bolt to 10 Nm (89 lb. in.). 4. Door regulator nuts. TIGHTEN ^ Nut to 10 Nm (89 lb. in.). 5. Door window assembly. 6. Door water deflector. 7. Door trim panel. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure Window Seal: Technical Service Bulletins Header Weatherstrip - Revised Replacement Procedure File In Section: 10 - Body Bulletin No.: 83-15-03 Date: August, 1998 SERVICE MANUAL UPDATE Subject: Section 10-13 - Revised Remove and Install Procedure for Header Weatherstrip and Retainers Models: 1995-98 Chevrolet Cavalier (Convertible Only) 1995-98 Pontiac Sunfire (Convertible Only) This bulletin is being issued to revise the remove and install procedure for header weatherstrip and retainers, convertible only, in Section 10-13 of the Service Manual. Procedure Header Weatherstrip and Retainers Remove or Disconnect Important: Removing the weatherstrip retainers is not necessary if only the weatherstrip is to be serviced. 1. Unlatch and lower folding top. 2. Windshield garnish molding. Refer to Windshield Garnish Molding in this section. 3. Push-pin retainers securing the header weatherstrip at top of the LH and RH A-pillars. 4. Clips securing the header weatherstrip at bottom of the LH and RH A-pillars. 5. Header weatherstrip by pulling up while separating the adhesive bond with a flat bladed tool. 6. Screws securing A-pillar weatherstrip retainer. 7. Screws securing header weatherstrip retainer. 8. Header weatherstrip retainer. 9. Header garnish molding retainer. Clean ^ Adhesive from parts that will be reused ^ Foam tape from parts that will be reused ^ Foam tape from header surface ^ Butyl tape from header surface Inspect ^ Header weatherstrip for holes, rips or breaks in the surface skin. If holes, rips or breaks are found, the weatherstrip must be replaced. Install or Connect Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11732 1. 50.8 mm (2 in.) long x 12.7 mm (1/2 in.) wide x 1.6 mm (1/16 in.) thick butyl tape to header surface centered over both ditch moldings. See Figures 1 and 2. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11733 2. 1,524 mm (60 in.) long x 25.4 mm (1 in.) wide x 3.2 mm (1/8 in.) thick PVC closed-cell foam tape centered side-to-side to header surface. See Figure 3. 3. 1,524 mm (60 in.) long x 12.7 mm (1/2 in.) wide x 1.6 mm (1/16 in.) thick butyl tape running from top end of one A-pillar weatherstrip retainer, up and across the header, overlapping the ditch moldings butyl and to the top edge of the other A-pillar. Do not remove the protective backing from the butyl tape at this time. See Figure 4. 4. Header weatherstrip retainer to header. 5. Screws securing header weatherstrip retainer. 6. Windshield garnish molding. Refer to Windshield Garnish Molding in this section. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11734 7. Continuous 4.8 mm (3/16 in.) diameter bead of pumpable butyl inside header weatherstrip retainer, out and down to both A-pillar weatherstrip retainers. See Figure 5. 8. Lay front header weatherstrip in position to the header retainer. 9. Push-pin retainers to secure LH and RH ends of weatherstrip to header corners. 10. Using a plastic trim stick or wheel-type installation tool, install the front of weatherstrip into the retainer. 11. Bottom clips of weatherstrip at the A-pillar. 12. Remove protective backing from the butyl tape. 13. Smooth out weatherstrip in the header retainer to work out any wrinkles along header and at the A-pillars. Ensure the A-pillar corners of weatherstrip do not excessively roll downward. Otherwise, the door glass, when closed, will pull seal downward more. 14. Pumpable butyl at LH and RH bottom ends of the A-pillar part of the weatherstrip. See Figure 6. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Header Weatherstrip - Revised Replacement Procedure > Page 11735 15. A-pillar part of the weatherstrip to weatherstrip retainer, using a plastic trim stick. 16. Weatherstrip all along the butyl strip. 17. Close convertible top and fully raise the door windows. Ensure the door window to A-pillar corner seal is a proper fit. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: Customer Interest Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 11744 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: Customer Interest Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11754 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: All Technical Service Bulletins Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 11763 Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: All Technical Service Bulletins Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit Windshield: All Technical Service Bulletins New Windshield/Glass Urethane Adhesive Caulking Kit File In Section: 10 - Body Bulletin No.: 83-15-16 Date: October, 1998 INFORMATION Subject: New Windshield and Stationary Glass Urethane Adhesive Caulking Kit Models: 1990-99 All Passenger Cars and Trucks As a result of a change from standard viscosity urethane to high-viscosity urethane, a new Urethane Adhesive Caulking Kit, P/N 12346392, is now available from GMSPO. This kit contains the "High Viscosity" Urethane Adhesive for thicker and more consistent bead size applications. When applied properly, this new high viscosity urethane in many instances will eliminate the need for depth setting blocks or the damming material to control squeeze out. The following is the contents of the new kit: Like the standard viscosity urethane contained in kit (P/N 12346284) that it replaces, it is a one-part, moisture cure product with curing times that vary as a result of changes in either temperature or humidity. THE REQUIRED TIME FOR THIS NEW ONE-PART MATERIAL to ensure a safe installation of stationary glass before returning the vehicle to the customer, IS A MINIMUM OF SIX (6) HOURS AT 70°F (21°C) AND 30% RELATIVE HUMIDITY. Alternate equivalent materials for this kit may be available from a local glass repair shop under the following product numbers: Other manufacturers of Urethane Adhesive that have documented their ability to meet or exceed General Motors specification # 3651M (Performance Requirements for Stationary Glass Bonding Adhesive System Service) are also considered to be equivalent to GM Kit (P/N 12346392). In previously published Corporate Bulletin Number 73-10-54, increasing customer demands for faster service have resulted in quicker two-part urethane adhesives to be made available. Essex Beta Seal U216* (two-part urethane adhesive) also meets the General Motors 3651M Specification and can be Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit > Page 11772 used when the customer demands quicker repair of the vehicle than the above described one-part product can provide. This two-part, chemical cure product requires ONE (1) TO ONE-AND-ONE-HALF (1-1/2) HOURS FOR CURING BEFORE RETURNING THE VEHICLE TO THE CUSTOMER. This two-part product also requires primers on the glass and pinchweld surfaces. The primers and applicator daubers are not included with this two-part product and therefore, must be purchased separately. In addition, this two-part product requires a special applicator (gun) for proper mixing and dispensing of the adhesive. Important: The U216 product is NOT available from GMSPO and must be obtained locally. * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such products which may be available from other sources. When using either of the above described products, make sure to follow the manufacturer's directions for application and drying times. For information regarding the removal and installation of stationary glass, consult the appropriate Service Manual. Parts information P/N Description 12346392 Urethane Adhesive Caulking Kit Parts are expected to be available from GMSPO, 10/12/98. Important: The previously recommended adhesive kit (P/N 12346284) will no longer be available from GMSPO once inventory is exhausted. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 72-05-04 > Aug > 97 > Warranty - Guidelines for Claiming Windshield Replace Windshield: All Technical Service Bulletins Warranty - Guidelines for Claiming Windshield Replace File In Section: Warranty Administration Bulletin No.: 72-05-04 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Claiming C0034 - Windshield Replacement Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with guidelines for using the above subject labor operations. In an effort to understand the windshield replacements, the following two phase approval process is being implemented. We feel this approach will allow GM to be responsive to repair decisions on vehicles over 10,000 miles (16,000KMS), while providing you, our dealers, the empowerment to address customer needs on those cases requiring repairs early in the vehicle's life, under 10,000 miles (16,000KMS). Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Windshield replacement on vehicles under 10,000 miles (16,0OOKMS) can only be made after Service Management inspection, review and approval. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. ^ Windshield replacement on vehicles over 10,000 miles (16,000KMS) can only be made after Service Management inspection, review and approval from the divisional service representative. Vehicles may be required to be held for wholesale inspection. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. The claim will require wholesale authorization for payment. Additional Requirements ^ Windshields replaced must be held for the normal parts retention period and the defect should be clearly identified on the glass by means of tape and/or a grease pencil. ^ Sublet windshield replacements, like other sublet repairs are to be claimed for actual dealership cost less any discounts and or allowances offered. Sublet repairs cannot exceed the normal allowance provided to the dealership had the repair been completed in-house. See your GM Policy and Procedure Manual for the complete guidelines. Windshields damaged by normal wear, road hazards, vandalism, or other physical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 73-10-54 > May > 97 > Windshield - Two-Part Urethane Adhesive For Installation Windshield: All Technical Service Bulletins Windshield - Two-Part Urethane Adhesive For Installation File In Section: 10 - Body Bulletin No.: 73-10-54 Date: May, 1997 INFORMATION Subject: Two-Part Urethane Adhesive For Windshield Installations Models: 1997 And Prior Passenger Cars and Trucks (Using Urethane Adhesive To Retain Windshields) General Motors passenger cars and trucks use urethane adhesive as a means to retain the windshield in the body opening. The urethane adhesive is used to bond the windshield in the opening, increasing vehicle structure. The current recommended urethane adhesive, GM P/N 12346284, is a one-part moisture cure product that requires a minimum curing period of 6 hours at room temperature before returning the vehicle to the customer. Increasing customer demands for faster service in recent years have resulted in quicker cure two-part urethane adhesives. Essex Beta Seal U216* (two-part urethane adhesive) meets the General Motors 3651M Specification (Performance Requirements for Stationary Glass Bonding Adhesive System Service) and can be used when the customer demands quicker repair of the vehicle than the current one-part materials can provide. Either of these products can be used when glass replacement is performed. The differences between these products are as follows: The CURRENT URETHANE ADHESIVE KIT, GM P/N 12346284, IS A ONE-PART ADHESIVE. It includes the necessary glass and pinchweld primers and is specified in Service Manuals for General Motors' vehicles. Since this is a "moisture cure" product, the curing time for this one-part material will vary with changes to either temperature or humidity. The REQUIRED TIME FOR THIS ONE-PART MATERIAL to ensure a safe installation of stationary glass before returning the vehicle to the customer IS A MINIMUM OF SIX (6) HOURS AT 70°F (21°C) AND 30% RELATIVE HUMIDITY. ESSEX BETA SEAL U216 IS A TWO-PART ADHESIVE MATERIAL THAT PROVIDES FOR A ONE (1) TO ONE AND ONE HALF (11/2) HOUR CURE BEFORE RETURNING THE VEHICLE TO THE CUSTOMER. This product also requires primers on the glass and pinchweld surfaces. This product requires a special applicator for the mixing and dispensing of the adhesive. When using this (or any) product, make sure to follow the manufacturer's directions for application and drying times. Parts Information Parts are currently available from GMSPO. * We believe this source and their product to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such products which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Wiper Blade: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11786 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > NHTSA96V16000 > Aug > 96 > Recall 96V16000: Incorrect Wiper Blades Wiper Blade: All Technical Service Bulletins Recall 96V16000: Incorrect Wiper Blades These vehicles were built with an incorrect wiper blade assembly (17" long instead of 22" long) on the driver's side. This does not comply with FMVSS No.104, "Windshield Wiping and Washing Systems." The area and pattern wiped on the windshield will be reduced and could affect the driver's view in wet weather increasing the risk of a vehicle accident. Dealers will inspect for the correct wiper blade assembly and install a correct length wiper blade assembly. Owner Notification: Owner notification began August 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > NHTSA96V160000 > Aug > 96 > Recall 96V160000: Windshield Wiper Blade Incorrect Wiper Blade: All Technical Service Bulletins Recall 96V160000: Windshield Wiper Blade Incorrect These vehicles were built with an incorrect wiper blade assembly (17" long instead of 22" long) on the driver's side. this does not comply with FMVSS No. 104, "windshield wiping and washing systems." The area and pattern wiped on the windshield will be reduced and could affect the driver's view in wet weather increasing the risk of a vehicle accident. Dealers will inspect for the correct wiper blade assembly and install a correct length wiper blade assembly. Owner Notification: Owner notification began August 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Washer Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper/Washer Switch Wiper Switch: Locations Windshield Wiper/Washer Switch LH I/P And Steering Column LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper/Washer Switch > Page 11813 Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11814 Wiper Switch: Service and Repair Since the Turn Signal Switch and Wiper Switch are part of the Steering Column, refer to STEERING COLUMN UNIT REPAIR for procedures and additional information. You may also need to refer to this area to remove other Steering Column components for access. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations LH Front Ahead Of Wheel Well Splash Shield Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 11818 Washer Pump Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 11819 Windshield Washer Pump: Service and Repair Description Remove or Disconnect 1. Negative battery cable from battery 2. Connector (1) from washer pump (2). 3. Hose (3) from washer pump (2). 4. Washer pump (2) from washer solvent container assembly (6). A. Pull top of washer pump (2) out from side of washer solvent container assembly (6). B. Pull washer pump (2) up out of washer solvent container assembly (6). Install or Connect 1. Washer pump (2) in washer solvent container assembly (6). A. Push washer pump (2) down into washer container assembly (6) completely. B. Push top of washer pump (2) into side of washer solvent container assembly (6). 2. Hose (3) to washer pump (2). 3. Connector (1) to washer pump (2). 4. Negative battery cable to battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations LH Front Lower Engine Compartment Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 11823 Windshield Washer Reservoir: Service and Repair Description Description Remove or Disconnect 1. Negative battery cable from battery. . Connector (1) from washer pump (2). 3. Hose (3) from washer pump (2). 4. Two screws (4), screw (5), and washer solvent container assembly (6) from vehicle. 5. Air induction assembly (7) and two retainers (8) from washer solvent container assembly (6). Install or Connect NOTICE: Refer to Fastener Notice. 1. Air induction assembly (7) on washer solvent container assembly (6) with two retainers (8). 2. Washer solvent container assembly (6) on vehicle with two screws (4) and screw (5). Tighten ^ Screws to 10 N.m (88 lb. in.). 3. Hose (3) to washer pump (2). 4. Connector (1) to washer pump (2). 5. Negative battery cable to battery. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair Windshield Washer Spray Nozzle: Service and Repair Wiper/washer system has a spray pattern that cleans 75% of the wipe pattern within ten wiper cycles. If a nozzle becomes plugged, apply air pressure. If the nozzle remains plugged, it must be replaced. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Washer Switch Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair Description Remove or Disconnect 1. Turn ignition switch to "ACCY" position. 2. Set wiper switch to "PULSE" position. 3. Turn ignition switch off when wiper arms are in the innerwipe position and not moving. 4. Washer hose (9) from washer nozzle. 5. Cover (10) from nut (11). 6. Nut (11) from wiper arm assembly (12) and wiper transmission assembly drive shaft (A). IMPORTANT ^ If wiper arm assembly cannot be removed from wiper transmission assembly drive shaft by rocking. special tool J 41401-4 may be used with the windshield wipers in midwipe. 7. Wiper arm assembly (12) from wiper transmission assembly drive shaft (A) by rocking. 8. Wiper blade assembly (13) from wiper arm assembly (12). A. Push in button (B) of wiper blade assembly clip (C) and remove wiperblade assembly (13) from inside radius of wiper arm assembly (12). B. Bring wiper arm assembly (12) out through opening in wiper blade assembly (13). Install or Connect NOTICE: Refer to Fastener Notice. 1. Wiper blade assembly (13) on wiper arm assembly (12). 2. Wiper arm assembly (12) on wiper transmission assembly drive shaft (A). A. Put ignition switch in "ACCY" position. B. Set wiper switch to "PULSE" position. Wind-shield wiper system should be operating. C. Turn ignition switch off when wipers are in the innerwipe position and not moving. IMPORTANT ^ Measuring device must be held at 90 degrees (perpendicular) to the wiper blade assembly (13). D. Install wiper arm assembly (12) on wiper transmission assembly drive shaft (A) while maintaining a distance of 87.8 mm (3.46 in.)(LH) or 97.5 mm (3.83 in.) (RH) between wiper blade assembly (13) and bottom of windshield. 3. Nut (11) on wiper transmission assembly drive shaft(A) and wiper arm assembly (12). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 11833 Tighten ^ Nut to 27 N.m (20 lb. ft.). 4. Cover (10) on nut (11). IMPORTANT ^ Lubricate washer hose with windshield washer solvent to ease installation on washer nozzle. 5. Washer hose (9) on washer nozzle. 6. Operate wipers and check for proper operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Recalls: > NHTSA96V16000 > Aug > 96 > Recall 96V16000: Incorrect Wiper Blades Wiper Blade: Recalls Recall 96V16000: Incorrect Wiper Blades These vehicles were built with an incorrect wiper blade assembly (17" long instead of 22" long) on the driver's side. This does not comply with FMVSS No.104, "Windshield Wiping and Washing Systems." The area and pattern wiped on the windshield will be reduced and could affect the driver's view in wet weather increasing the risk of a vehicle accident. Dealers will inspect for the correct wiper blade assembly and install a correct length wiper blade assembly. Owner Notification: Owner notification began August 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Recalls: > NHTSA96V160000 > Aug > 96 > Recall 96V160000: Windshield Wiper Blade Incorrect Wiper Blade: Recalls Recall 96V160000: Windshield Wiper Blade Incorrect These vehicles were built with an incorrect wiper blade assembly (17" long instead of 22" long) on the driver's side. this does not comply with FMVSS No. 104, "windshield wiping and washing systems." The area and pattern wiped on the windshield will be reduced and could affect the driver's view in wet weather increasing the risk of a vehicle accident. Dealers will inspect for the correct wiper blade assembly and install a correct length wiper blade assembly. Owner Notification: Owner notification began August 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Wiper Blade: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11851 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > NHTSA96V16000 > Aug > 96 > Recall 96V16000: Incorrect Wiper Blades Wiper Blade: All Technical Service Bulletins Recall 96V16000: Incorrect Wiper Blades These vehicles were built with an incorrect wiper blade assembly (17" long instead of 22" long) on the driver's side. This does not comply with FMVSS No.104, "Windshield Wiping and Washing Systems." The area and pattern wiped on the windshield will be reduced and could affect the driver's view in wet weather increasing the risk of a vehicle accident. Dealers will inspect for the correct wiper blade assembly and install a correct length wiper blade assembly. Owner Notification: Owner notification began August 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 CHEVROLET CAVALIER Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > NHTSA96V160000 > Aug > 96 > Recall 96V160000: Windshield Wiper Blade Incorrect Wiper Blade: All Technical Service Bulletins Recall 96V160000: Windshield Wiper Blade Incorrect These vehicles were built with an incorrect wiper blade assembly (17" long instead of 22" long) on the driver's side. this does not comply with FMVSS No. 104, "windshield wiping and washing systems." The area and pattern wiped on the windshield will be reduced and could affect the driver's view in wet weather increasing the risk of a vehicle accident. Dealers will inspect for the correct wiper blade assembly and install a correct length wiper blade assembly. Owner Notification: Owner notification began August 1996. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chevrolet at 1-800-222-1020. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Wiper Blade: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 11865 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Element Replacement Wiper Blade: Service and Repair Wiper Blade Element Replacement Description Description Remove or Disconnect 1. Wiper blade assembly (13) from wiper arm assembly (12). IMPORTANT ^ Wiper blade element must be replaced if removed from wiper blade assembly. 2. Wiper blade element (14) by pulling out through wiper blade assembly claws (D). Install or Connect 1. Wiper blade element (14) in wiper blade assembly (13). A. Slide wiper blade element (14) through wiper blade assembly claws (D) until claw (D) is locked into notches (E) in wiper blade element (14). 2. Wiper blade assembly (13) to wiper arm assembly 12). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Element Replacement > Page 11868 Wiper Blade: Service and Repair Wiper Blade Assembly Replacement Description Remove or Disconnect 1. Turn ignition switch to "ACCY" position. 2. Set wiper switch to "PULSE" position. 3. Turn ignition switch off when wipers are in the innerwipe position and not moving. 4. Wiper blade assembly (13) from wiper arm assembly (12) A. Push in button (B) of wiper blade assembly clip (C) and remove wiper blade assembly (13) from inside radius of wiper arm assembly (12). B. Bring wiper arm assembly (12) out through opening in wiper blade assembly (13). Install or Connect 1. Wiper blade assembly (13) on wiper arm assembly (12). 2. Operate wipers and check for proper operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair Figure 10 Figure 11 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 11872 Figure 12 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 11873 Figure 13 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 11874 Figure 14 Figure 15 Figure 18 Remove or Disconnect 1. Wiper arm assemblies from wiper transmission assembly drive shafts. 2. Four screws (15), five retainers (16). and air inlet screen assembly (17) from vehicle. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 11875 3. Connector (18) from wiper motor assembly (19). 4. Three screws (20) and wiper drive system module (21;) from vehicle. 5. Wiper transmission assembly (22) from wiper motor crank arm assembly (23) using tool J 39232. 6. Cap (27) from wiper transmission assembly (22). 7. Four screws (28) and wiper transmission assembly (22) from tube frame (26). 8. Three grommets (29. 30, and 31) from tube frame (26) and wiper transmission assembly (22). 9. Wiper motor assembly from tube frame. Install or Connect NOTICE: Refer to Fastener Notice. 1. Three grommets (31, 30, and 29) on tube frame (26) and wiper transmission assembly (22). 2. Wiper motor assembly on tube frame. 3. Crank arm assembly on wiper motor assembly. 4. Wiper transmission assembly (22) on tube frame (26) with four screws (28). Tighten ^ Screws to 9 N.m (79 lb. in.). 5. Cap (27) on wiper transmission assembly (22). 6. Wiper transmission assembly (22) on wiper motor crank arm assembly (23) using tool J 39529. 7. Wiper drive system module (21) on vehicle with three screws (20). Tighten ^ Screws to 10 N.m (88 lb. in.). 8. Connector (18) on wiper motor assembly (19). 9. Air inlet screen assembly (17) on vehicle with four screws (15) and five retainers (16). 10. Wiper arm assemblies on wiper transmission assembly drive shafts. 11. Operate wipers and check for proper operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations LH Rear Engine Compartment-Front Of Dash Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor Wiper Motor: Service and Repair Front Wiper Motor Figure 10 Figure 11 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11881 Figure 12 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11882 Figure 13 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11883 Figure 14 Figure 15 Remove or Disconnect 1. Wiper arm assemblies from wiper transmission assembly drive shaft. 2. Four screws (15), five retainers (16), and air inlet screen assembly (17) from vehicle. 3. Connector (18) from wiper motor assembly (19). 4. Three screws (20) and wiper drive system module (21) from vehicle. 5. Wiper transmission assembly (22) from wiper motor crank arm assembly (23) using tool J 39232. 6. Wiper motor crank arm assembly (23) from wiper motor assembly (19). A. Loosen screw (24). B. Tap on screw (24) with a soft-faced mallet while holding up on wiper motor crank arm assembly (23) until wiper motor crank arm assembly (23) is loose on wiper motor assembly (19). C. Remove screw (24) and wiper motor crank arm assembly (23) from wiper motor assembly (19). 7. Three screws (25) and wiper motor assembly (19) from tube frame (26). Install or Connect NOTICE: Refer to Fastener Notice. 1. Wiper motor assembly (19) on tube frame (26) with three screws (25). Tighten ^ Screws to 7 N.m (62 lb. in.). 2. Wiper motor crank arm assembly (23) on wiper motor assembly (19). A. Connect connector (18) to wiper motor assembly (19). B. Put ignition switch in "ACCY" position. C. Set wiper switch to "PULSE" position. Wiper motor assembly (19) should be operating. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11884 D. Turn off ignition switch while wiper motor is stopped in innerwipe position. E. Disconnect connector (18) from wiper motor assembly (19). NOTICE: Do not rotate wiper motor assembly shaft during installation of wiper motor crank arm assembly. F. Install wiper motor crank arm assembly (23) on wiper motor assembly (19) while maintaining a 4-8 mm (.157 - .315 in.) gap between wiper motor crank arm assembly (23) and bracket tab (F). G. Install screw (24). H. Check gap between wiper motor crank arm assembly (23) and bracket tab (F). If gap is not 4-8 mm(.157-.315 in.)remove crank arm assembly (23) and repeat installation step 2. Tighten ^ Screw to 16 N.m (144 lb. in.). 3. Wiper transmission assembly (22) on wiper motor crank arm assembly (23) using tool J 39529. 4. Wiper drive system module (21) on vehicle with three screws (20). Tighten ^ Screws to 10 N.m (88 lb. in.). 5. Connector (18) on wiper motor assembly (19). 6. Screen assembly (17) on vehicle with four screws (15) and five retainers (16). 7. Wiper arm assemblies on wiper transmission assembly drive shaft. 8. Operate wipers and check for proper operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11885 Wiper Motor: Service and Repair Wiper Motor Cover Replacement Figure 10 Figure 11 Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 11886 Figure 16 Remove or Disconnect 1. Wiper arm assemblies from vehicle. 2. Four screws (15). five retainers (16). and screen assembly (17) from vehicle. 3. Connector (18) from wiper motor assembly (19). 4. Three screws (20) and wiper drive system module (21) from vehicle. 5. Three screws (32) and pulse circuit board and cover assembly (33) from wiper motor assembly (19) Install or Connect NOTICE: Refer to Fastener Notice. 1. Pulse circuit board and cover assembly (33) on wiper motor assembly (19) with three screws (32). Tighten ^ Screws to 2 N.m (18 lb. in.). 2. Wiper drive system module (21) on vehicle with three screws (20). Tighten ^ Screws to 10 N.m (88 lb. in.). 3. Connector (18) to wiper motor assembly (19). 4. Screen assembly (17) on vehicle with four screws (15) and five retainers (16). 5. Wiper arm assemblies on vehicle. 6. Operate wipers and check for proper operation. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers - Revised Cleaning Of Wiper Drive Shaft Knurls Wiper Motor Linkage: Technical Service Bulletins Wipers - Revised Cleaning Of Wiper Drive Shaft Knurls File In Section: 8 - Chassis/Body Electrical Bulletin No.: 73-82-03 Date: April, 1997 SERVICE MANUAL UPDATE Subject: Section 8EI8E1 - Revised Cleaning Procedure For Wiper Drive Shaft Knurls Models: 1997 Buick Century, Park Avenue 1988-97 Buick Regal 1994-97 Chevrolet Camaro 1995-97 Chevrolet Cavalier 1990-97 Chevrolet Lumina 1990-96 Chevrolet Lumina APV 1997 Chevrolet Malibu 1995-97 Chevrolet Monte Carlo 1997 Chevrolet Venture 1997 Oldsmobile Cutlass 1988-97 Oldsmobile Cutlass Supreme 1990-97 Oldsmobile Silhouette 1994-97 Pontiac Firebird 1988-97 Pontiac Grand Prix 1995-97 Pontiac Sunfire 1990-97 Pontiac Trans Sport 1997 Chevrolet and GMC G Van 1994-97 Chevrolet and GMC S/T Models 1994-97 Oldsmobile Bravada This bulletin is being issued to revise the cleaning procedure for wiper drive shaft knurls in Section 8E (passenger cars) and 8E1 (trucks) of the Service Manual. Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers - Revised Cleaning Of Wiper Drive Shaft Knurls > Page 11891 Please update the procedure in the appropriate Service Manuals as follows: (See Figure 1) Knurls of the wiper transmission drive shaft must be cleaned when wiper arm is removed. Clean knurls of transmission drive shaft with a suitable wire brush. Notice: (For 1995-97 U Van ONLY): DO NOT use J 6627-4 for removal of wiper arms. Vehicle paint will be scratched if use of this tool is attempted. Use a suitable battery terminal puller for removal of wiper arms. (See Figure 2). Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper/Washer Switch Wiper Switch: Locations Windshield Wiper/Washer Switch LH I/P And Steering Column LH Passenger Compartment Steering Column Chevrolet Cavalier Workshop Manual (L4-144 2.4L DOHC VIN T SFI (1997)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Windshield Wiper/Washer Switch > Page 11896 Steering Column